Research and development
AGV helmets that reach the market are the result of a meticulous development process which uses the most innovative methods and technologies. AGV Extreme Standards helmets and all other models are made in specialised laboratories where all the manufacturing stages are managed from design to actual production.
The development of a helmet starts with FEM Analysis (Finite Elements Method), a fully digital CAE/CAD design process that is essential for optimising the structure of the helmet.
A helmet must protect without being heavy. To optimise impact absorption capacity in relation to weight, the greatest possible number of tests with materials and different layers must be carried out.
FEM analysis allows all the tests needed to be carried out on a helmet that is reproduced using a mathematical model. Using this sophisticated method, AGV can test various materials and different combinations in a series of crash tests before even beginning to make the moulds needed for production purposes. A virtually unlimited number of helmets can therefore be tested to more quickly and accurately assess both the shell and the impact absorption material and to create a blueprint for a helmet that provides maximum protection.
FEM analysis and the results obtained indicate if the structure of the helmet needs to be modified to obtain the performance characteristics demanded by AGV which are much stricter than those currently in force.
The digital blueprint of the helmet also allows aesthetic and functional parameters to be assessed including tests for fit and in the wind tunnel while avoiding the times and costs involved in creating moulds.
The mechanical design stage includes any requirements for modifications that might be needed and is necessary to accurately define the dimensions useful to create moulds. With these issues resolved, the design and creation of moulds can go ahead.
Once the moulds have been made, the test phase can begin. For AGV helmets, this phase include:
- Durability tests
- Material tests
- Visual tests to ensure no distortion occurs on visors
- Paint resistance tests
- Wind tunnel tests
In the wind tunnel tests parameters for dynamic comfort, i.e. the aerodynamics, noise and ventilation of the helmet, are scientifically measured.
The production of AGV helmets is performed by modern machines and state-of-the-art control systems. The new technologies used have low environmental impact and the paint machines use solvent free paints that do not harm the environment as well as a residue recovery system.
The production of AGV helmets involves the following stages:
- The positioning of components: the first stage of the production of a fibre helmet is the positioning of fibre components in the mould.
- Identification microchip: the helmet's "identity card" which contains all the information relating to production and to the technical characteristics, is inserted in the layers of the shell.
- Moulding the shell
- Cutting the shell with water: this is performed with very high pressure water jets on a computer controlled machine
- Component assembly: involves fitting electronic components inside the helmet such as the SHARE communications system.
- Component tests and checks: this final stage of production involves tests to check that electronic components are working properly, weighing to ensure the helmet complies with parameters and the fitting of additional mechanical components such as air intakes and the visor mechanism.