Every AGV helmet sold is the result of a meticulous development process involving cutting-edge processes and technologies. AGV Extreme Standards helmets – and all other models – are developed in specialized laboratories that manage all phases of helmet production, from conception to manufacturing.


Helmet development begins with FEM (Finite Elements Method) analysis, an entirely digitalized CAE/CAD design process that is crucial to optimize the structure of the helmet.

The helmet must protect without being heavy. To optimize the ratio of impact absorption capacity to weight, we need to carry out as many tests as possible with different materials and layering.

FEM analysis allows us to perform all the necessary tests using a helmet that is reproduced using a mathematical model. Using this sophisticated process, we can assess different materials and combinations of materials in a series of crash tests, before we even start creating the molds to actually produce the helmet. We can test the helmet a virtually infinite number of times, assessing both the shell and the absorption material faster and more thoroughly, which in turn allows us to come up with a more protective final design.

FEM analysis shows whether the helmet structure needs to be changed to obtain the performance levels that AGV demands, which are stricter than current standards. By using a digital representation of the helmet, we can also carry out aesthetic and functional assessments – including tests on fit and wind tunnel testing – without the time and cost involved in creating molds.


The mechanical design phase incorporates any changes that may be required, generating the final measurements to use when producing the molds. The molds are then designed and created on this basis.


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Once the molds are produced, the testing phase begins. The tests carried out on AGV helmets include:

  • Durability tests
  • Materials tests
  • Optical tests to check for no visor distortion
  • Paint resistance tests
  • Wind tunnel tests

Dynamic comfort parameters – aerodynamics, noise and ventilation – are scientifically measured in the wind tunnel.

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AGV produces helmets using modern machinery and cutting-edge quality control systems. The new technologies we use have a low environmental impact: the painting system uses paints with no environmentally damaging solvents and also features a waste recovery mechanism.

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AGV helmet production can be broken down into the following phases:

  • Positioning of components: the first phase in producing a carbon-fiber helmet is positioning the carbon-fiber components in the mold.
  • Identification microchip: the helmet’s very own “ID”, containing all the information on its production and technical characteristics, is inserted into the layering of the shell.
  • Molding of the shell
  • Water jet cutting of the shell: carried out using a high-pressure water jet with fully computerized equipment
  • Component assembly: insertion of electronic components into the helmet, such as the SHARE communication system.
  • Component tests and checks: the final production phase involves tests to check that the electronic systems work properly, weighing to ensure that parameters are met, and inserting additional mechanical components such as air vents and the visor mechanism.

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