Vega Helmets factory visit reveals lightweight carbon-fibre

Vega Helmets, one of India's largest helmet makers, produces 25,000 units daily across six plants. A visit to its Belagavi facility revealed the scale of its in-house manufacturing, from shell moulding to final assembly.

Vega manufactures nearly every component internally. Plastic pellets are injection-moulded into an ABS helmet shell in just 90 seconds. The painting process is largely manual, though an automated machine applies clear coat. Thousands of painted shells for brands like KTM, TVS Racing, Royal Enfield, and Ather await assembly on the factory floor.

Making carbon-fibre shells

The most advanced production occurs on the factory's top floor. Here, Vega uses balloon moulding technology to create fibreglass and carbon-fibre shells. The company has made carbon-fibre helmets since 1999. A tri-composite structure of carbon fibre, aramid, and fibreglass balances lightness and impact absorption.

Vega recently invested in a CNC water jet machine to cut visor apertures and vent holes in carbon-fibre shells. The company says this improves tolerances and should address customer complaints about excessive wind noise in current Axor carbon models.

Production of these premium shells is slow. The company can currently make up to eight carbon-fibre helmets per day. This longer manufacturing time is one reason behind the high price of its latest model, the Axor MX Carbon, which costs Rs 20,000.

Testing the Axor MX Carbon

It is available in three shell sizes, with a weight of approximately 1,040 grams, plus or minus 50 grams depending on size. A brief test at an off-road facility revealed its light weight and good balance.

The inner liner was softer and more comfortable than expected. Fit was generally very good for a size S, though the tester noted the tips of their ears made contact with the liner. The double D-ring closure was easy to use, but the snap button securing the strap lacked positive feedback when engaged.

Overall quality is acceptable for the price, according to the source. However, the finishing where carbon-fibre panels join along the helmet's centre was inconsistent across different units.

Future plans for premium helmets

Vega is confident demand for premium helmets will grow with India's evolving two-wheeler market. The company plans to introduce more models soon, including an ADV-style helmet. It is reportedly working on making FIM-homologated and Snell-approved performance helmets, though this could take a couple of years.

The prospect of reasonably priced, fully locally manufactured carbon-fibre helmets is now a reality from this Indian heavyweight.