EN1078 Camera GPS Smart bicycle helmet RAW3

Factory Production Capacity

Factory Size & Workforce

• Total area: 18,000 m²

• Total employees: 210

• Dongguan Factory: approx. 200 staff (50 office staff, 150 production workers)

• Yueyang Factory: approx. 150 staff (35 office staff, 115 production workers)

Production Equipment & Capabilities
In-house capabilities include mold manufacturing, printing, vacuum forming, injection molding, in-mold production, painting, labeling, and packaging (partial outsourcing for specialized packaging).

Production Capacity

• Daily Output: 5,000 helmets

• Monthly Output: approx. 150,000 helmets

Quality Control Process

1. Pre-production sample completed before mass production

2. Customer approval based on signed sample

3. Mass production strictly follows approved reference

4. Third-party inspection arranged by customers (full inspection or random sampling) before shipment

International Certifications
CE EN1078 | CPSC | ASTM | AS/NZS | UKCA

Annual Sales Turnover
Approx. RMB 95 million

Main Product Categories

• Bicycle helmets

• Ski helmets

• Equestrian helmets

• Riot helmets

• Industrial safety helmets

• Climbing helmets

• Water sports helmets

• Skydiving helmets

Export Markets
Switzerland, Sweden, Czech Republic, Germany, United Kingdom, United States, Japan, Norway, Italy, France, Netherlands, Indonesia, Singapore, Thailand, and Australia

Key Partners & Brands

• SWEET (Norway): Ski helmets, cycling helmets, water helmets, protective helmets

• AGU (Netherlands): Cycling helmets, safety helmets

• GIANT (China): Bicycle helmets, safety helmets

• LIIMAR (Italy): Cycling helmets, safety helmets

Quality You Can Trust

Every CGPRO helmet passes through over 36 quality control checkpoints to ensure maximum safety, comfort, and performance — because protecting your head is our top priority.

Helmet Quality Control Process

At CGPRO Helmets, every helmet undergoes a comprehensive, multi-stage quality inspection process to ensure consistent safety, durability, and international compliance. From raw material to final packaging, we enforce strict control measures to guarantee outstanding product quality for global clients.

1. Incoming Quality Control (IQC)

All raw materials are tested upon arrival to meet strict safety and performance criteria.

EPS foam density & consistency

PC/ABS shell material verification (impact & burn test)

Webbing and buckle tensile strength testing

Non-toxic ink & decal inspection (odor and adhesion check)

2. In-Process Quality Control (IPQC)

We implement process checks at each key production stage to prevent defects from entering the next phase.

Injection molding: Surface flatness, no cracks or shrink marks

EPS shaping: Uniform thickness and bonding quality

In-mold shell & EPS bonding strength

Interior padding alignment, sewing, and glue adhesion

3. Final Quality Control (FQC)

Before packaging, all helmets are fully inspected for overall quality, fit, and function.

100% visual inspection for appearance

Shell stability and deformation test

Strap & adjustment system function test

Size and fitting confirmation using model headforms

4. Laboratory Testing (EN/ASTM/CE/ISO Standards)

Our in-house lab and third-party partners conduct critical safety tests in accordance with international certifications.

Impact absorption test (EN1078 / ASTM F1447 / EN397)

Penetration resistance (EN12492 / EN1385)

Chin strap strength and retention system durability

High/low temperature resistance and UV stability

5. Outgoing Quality Control (OQC)

Before shipping, we conduct random sampling inspections to ensure batch consistency and package integrity.

AQL-based visual & functional check

Barcode, label, and accessory verification

Final inspection report and shipping approval

Case: OEM Polo Helmet with Carbon Fiber Shell & Retractable Visor

Client Need:
In July 2024, a Dubai-based polo helmet client approached us, seeking an OEM & ODM manufacturer capable of delivering a fully customized solution. Their requirements included a wide brim, retractable sun visor, lightweight design, and certification under PAS and SEI standards.

Our Solution:
After a detailed review of the client’s needs, we created a 3D model and produced 3D-printed prototypes to confirm structure and aesthetics. Upon approval, we developed four size molds. To ensure certification readiness while achieving lightweight performance, we recommended a 100% carbon fiber outer shell paired with a high-performance, lightweight EPP liner. The retractable visor was engineered as a signature feature of the helmet.

Result:
The helmet is currently in the testing phase. The client has expressed strong satisfaction with the design and engineering approach, and collaboration is expected to expand once certification is complete.