A helmet is born: Kask’s Protone from start to finish

<source media="(max-width: 320px)" srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=90&resize=160%2C208, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=320%2C416 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=480%2C624 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=640%2C832 4x" type="image/jpeg"> <source media="(max-width: 375px)" srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=90&resize=190%2C247, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=380%2C494 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=570%2C741 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=760%2C988 4x" type="image/jpeg"> <source media="(max-width: 425px)" srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=90&resize=215%2C279, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=430%2C559 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=645%2C838 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=860%2C1118 4x" type="image/jpeg"> <source media="(max-width: 768px)" srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=90&resize=295%2C383, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=590%2C767 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=885%2C1150 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=1180%2C1534 4x" type="image/jpeg"> <source media="(max-width: 992px)" srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=90&resize=136%2C176, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=272%2C353 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=408%2C530 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=544%2C707 4x" type="image/jpeg"> <source media="(min-width: 993px)" srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=90&resize=155%2C201, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=310%2C403 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=465%2C604 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=45&resize=620%2C806 4x" type="image/jpeg"> <img class="wp-image-301407 size-portrait_thumbnail image-handler__image image-handler__image--aspect no-wrap js-gallery-grid-src-image" src="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/30-1499684268184-1vnwosn6zw26e-734e08c.jpg?quality=90&resize=556%2C723" width="556" height="723" data-crop-width="" data-crop-height="" alt="Here a worker inspects a batch of shells in one of many quality control steps used throughout the construction process" title="30-1499684268184-1vnwosn6zw26e-734e08c" style="width: auto; height: 100%;"> Here a worker inspects a batch of shells in one of many quality control steps used throughout the construction process Oliver Woodman / Immediate Media

BikeRadar recently visited Kask’s production facility in Italy where we learned how a modern in-mould helmet is produced.

The exact model, whose production we shadowed, was Kask’s long running and successful Protone road lid. It’s this process, and slight variations of it, that sees Kask produce around 800,000 helmets a year in Italy.

You can think of a modern in-mould helmet as being made of two key parts: the shell and the liner. We kick off with the production of the shell below.

Thermoforming

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/14-1499424000831-1buihgy2v89g2-566c605.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> KASK’s Protone starts out life as a single polycarbonate sheet Oliver Woodman / Immediate Media The shell of our helmet starts off life as a single polycarbonate sheet. One that is then loaded into a large printing machine. Paint is then added by hand into the machine using pre-mixed colours.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499424095478-68rcw14w0iv1-19e391a.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> Paint is then applied using a large printing machine Oliver Woodman / Immediate Media Multiple layers of paint are often used to achieve the correct finish, with certain fluoro colours requiring this process to be completed seven times! Each layer of paint takes approximately 40 minutes to dry.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/13-1499424375237-m6rrm4br7iss-3a8ffa0.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> Once the correct finish is achieved the polycarbonate is then ready for vacuum forming Oliver Woodman / Immediate Media The sheets can then be loaded into the manufacturer’s vacuum forming machine where the polycarbonate is heated to around 90 degrees before it is drawn over a helmet-shaped mould as air is quickly removed.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/15-1499424492893-1l2r33m406zmx-066a45b.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> The sheets are loaded in place at the vacuum forming machine, beneath them are two helmet-shaped moulds Oliver Woodman / Immediate Media <source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499424492893-1m9kwbxsj0g3t-33049e4.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> Heat is applied and then… Oliver Woodman / Immediate Media <source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/17-1499424492897-sn3t0dinxai3-42f7273.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> The heated polycarbonate is drawn over a helmet-shaped mould Oliver Woodman / Immediate Media <source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/21-1499680764760-7otmautatgd-28b0080.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> A significant part of the helmet’s shell is now visible Oliver Woodman / Immediate Media The raised section of polycarbonate sheet — part of the shell — must then be cut from the excess material that surrounds it.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/24-1499681447197-12j744kvyiof0-82e14e0.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> The vacuum-formed shell sections must then be lifted from the moulds and trimmed from the sheet Oliver Woodman / Immediate Media Other sections of the shell are produced in the same way but require additional finishing. These parts are placed onto a wooden mould while a pre-programmed CNC machine makes precision cuts to the plastic for any vents or edges.

Please don’t be confused by the altering colours here, the factory handles many different colour options!

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/26-1499681654625-rtdhk1moe0v4-3da99ed.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> More intricate parts are finished by a CNC cutter Oliver Woodman / Immediate Media Suddenly things start to look a whole lot more helmet-like. <source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/29-quality-inpection-1499681778540-1rcq7h1g7mj3w-01fdea7.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> Shell components are then quality inspected before being packaged in preparation for the next manufacturing process Oliver Woodman / Immediate Media

In-moulding The helmet’s liner is made by expanding granules of EPS foam within a mould. The powdered foam expands when it is subjected to a combination of steam and pressure.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/2-1499682030742-1ozvswadriik5-6162ccd.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> The EPS foam arrives in powdered form before it expands into small spheres with the application of steam and heat Oliver Woodman / Immediate Media The expanded polystyrene (EPS) beads arrive in powdered form and are stored in vast vats at one side of the factory, and are divided into different types and densities.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/1-1499682124410-1hr7zscrpcyma-dd418a7.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> A vast network of vats contain foam of various types and densities Oliver Woodman / Immediate Media Steam is applied to the sherbet-like polystyrene, which then causes each one to expand significantly. After a few hours of rest these beads adopt the correct shape and are ready for the next step of the process.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/6-1499682224956-1shwi16kfkkle-cd75211.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> The components we saw earlier are then loaded into a machine alongside these additional plastic parts Oliver Woodman / Immediate Media The shell we made earlier is then placed into a mould along with various pre-made plastic components. These plastic inserts form part of a structurally significant skeleton-like form within the helmet’s liner and are often necessary to keep helmets with large vents from separating in case of an impact. Unfortunately, what takes place next I wasn’t allowed to photograph, but it’s best described as making a big helmet sandwich.

Two opposing sides of a large and scary machine are loaded with what will effectively become the top and bottom of the helmet. Then, once all human limbs are out of the way, the machine comes together in a way that’s reminiscent of the trash compactor scene in the first Star Wars film.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/8-quality-inspection-1499682794339-1dfxkifotfncw-0fc48b9.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> A few gentle taps with a mallet is all that is required to separate the helmet from its mould Oliver Woodman / Immediate Media Lots of hissing and flicking dials confirm that the polystyrene beads are making their way into the now closed mould. Approximately six minutes later and the halves separate once more, leaving a combined shell and liner in the form of a helmet that is very nearly complete.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/7-1499682448378-1mp62jtt0s9p7-5a73d14.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> Two halves and many components are combined as heated EPS beads fuse together to form the helmet’s shape Oliver Woodman / Immediate Media <source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/16-1499683869001-4qa9cr95gosx-dfd6447.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> No straps or stickers yet but the Protone is nearly complete Oliver Woodman / Immediate Media The helmet can now be gently prised from its inner mould, and is then kept in a dehumidified environment to remove any moisture.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=900%2C506 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=1200%2C675 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=900%2C506 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=1200%2C675 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=710%2C399 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=1065%2C599 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=1420%2C799 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=710%2C399 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=1065%2C599 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=1420%2C799 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=810%2C456 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=1215%2C683 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=1620%2C911 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=810%2C456 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=1215%2C683 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=1620%2C911 4x" type="image/jpeg"> <source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=816%2C459 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=1224%2C689 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?webp=true&quality=45&resize=1632%2C918 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=816%2C459 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=1224%2C689 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/finalassembly-1499683011740-csjvz5e1qq96-0f4a522.jpg?quality=45&resize=1632%2C918 4x" type="image/jpeg"> Finishing details and final quality inspections are then all that is required before the helmets become company stock Oliver Woodman / Immediate Media The lids are then shipped to another facility where the chin strap, retention system, padding and stickers are applied. Finally, quality control checks are completed before the helmet makes its way onwards through Kask’s distributor networks and eventually onto the heads of riders.

<source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1200%2C676 4x" type="image/webp"><source media="(max-width: 320px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=90&resize=300%2C169, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=600%2C338 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=900%2C507 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1200%2C676 4x" type="image/jpeg"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1420%2C800 4x" type="image/webp"><source media="(max-width: 375px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=90&resize=355%2C200, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=710%2C400 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1065%2C600 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1420%2C800 4x" type="image/jpeg"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1620%2C913 4x" type="image/webp"><source media="(max-width: 425px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=90&resize=405%2C228, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=810%2C457 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1215%2C685 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1620%2C913 4x" type="image/jpeg"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=2216%2C1249 4x" type="image/webp"><source media="(max-width: 589px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=90&resize=554%2C312, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1108%2C625 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1662%2C937 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=2216%2C1249 4x" type="image/jpeg"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=2480%2C1398 4x" type="image/webp"><source media="(min-width: 992px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=90&resize=620%2C350, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1240%2C699 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1860%2C1049 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=2480%2C1398 4x" type="image/jpeg"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1632%2C920 4x" type="image/webp"><source media="(min-width: 768px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=90&resize=408%2C230, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=816%2C460 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1224%2C690 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1632%2C920 4x" type="image/jpeg"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?webp=true&quality=45&resize=2224%2C1254 4x" type="image/webp"><source media="(min-width: 590px)" data-srcset="https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=90&resize=556%2C313, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1112%2C627 2x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=1668%2C940 3x, https://images.immediate.co.uk/production/volatile/sites/21/2019/03/warehouse-1499683151081-1qngj67z22dv0-9a8ef89.jpg?quality=45&resize=2224%2C1254 4x" type="image/jpeg"> Kask produces around 800,000 helmets a year Oliver Woodman / Immediate Media