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These helmets are made from thermoplastic, a single-layer, injection molded material. Due to its single-layer construction, a thermoplastic helmet requires a larger inner impact liner, which in turn increases the shell size and weight.
So the reason a lot of helmets are bigger is due to the shell construction materials. When going to a carbon fiber, or fiberglass matte, the inner liner can be made smaller.
Carbon fiber helmets are made of multiple layers of extremely strong, carbonized KevlarŽ fibers, along with multiple layers of resin. Due to the inherent strength of both carbon and Kevlar, less material is needed to achieve maximum helmet performance, strength and durability. As a result, carbon fiber helmets are significantly more lightweight than a comparable thermoplastic or fiberglass shell
Course, that last quote is talking about helmets in the 250 dollar and up price range.
I tried to order an outlaw CF, but large is out of stock. Still the best price I've seen so far on CF helmets, and lighter and smaller. Seems the cheaper you go, in most cases, the more bobble headed you'll be for the same protection. I guess there's a method to the madness.
Glad I got my large in time. My Nov is also some type of fiber. Maybe that's why it held up so well in my accident. It's not blow molded plastic like the rest. I actually sanded it down to repaint it and noticed it had a few layers to it.
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