A Winning Decal Material Solution for Sports Helmets

The Project

A leading manufacturer of helmets for professional and collegiate football and hockey teams needed a decal material capable of delivering reliable performance on their state-of-the-art sports helmet designs. 

Sports helmets are designed for safety, but they also play a critical role in team identity through prominently displayed team logos and graphics. They must also meet specific league brand identification standards.

The manufacturer required a decal solution that could provide ease of application, maintain a professional appearance, withstand demanding use conditions, and preserve the high visibility required for team graphics.

The Challenge

Protective helmets incorporate complex curves, ledges, ventilation openings, and recessed areas that can create challenges for decal application. Traditional helmet decal materials can have issues adhering to these varied, highly contoured helmet surfaces. The decals must also remain securely adhered to the surface and legible throughout the harsh conditions encountered during the helmet's intended use.

The manufacturer tried other materials available but was unable to find the best material that would work on their wide range of sports helmet types. 

The manufacturer needed decal materials that could:

• Conform to the aggressive curves and contours without lifting or bubbling.
• Maintain adhesion on varied hard helmet surfaces.
• Resist rain, sunlight, moisture, and other common outdoor exposure conditions typical in sports practice and game day use.
• Withstand impact, friction, and abrasion during regular use and handling.
• Preserve graphic integrity and visual appeal throughout the life of the decal.
• Meet league branding and identification requirements.

They also needed graphics that remained highly visible from the sidelines, stands, and television broadcasts, making print quality just as important as durability.

The Process

The client approached Flexcon seeking a durable, highly conformable decal material that could adhere to their designs for modern sports helmets.

Flexcon's technical team began by reviewing the application's key performance requirements, including:

• Surface type
• Degree of conformability required
• Environmental exposure conditions
• Printing process requirements
• Long-term durability expectations

Plasticizers in vinyls can cause challenges, which the team took into consideration when selecting the adhesive. 

In addition to adhesion and durability requirements, the client emphasized the need for exceptional print quality. Team logos must meet certain standards and serve as a primary form of brand identification. They must remain crisp, vibrant, and easily recognizable from a distance for spectators, television viewers, and game personnel.

By evaluating the application's requirements for adhesion performance, graphics quality, durability, longevity, and compliance considerations, Flexcon's technical experts were able to recommend a solution tailored to the client's needs.

The Result

The client was impressed with the quality and performance of the recommended ConformCal™ material. They were pleased that the decals maintained the appearance and visibility required for team branding while providing the durability needed to withstand outdoor exposure, handling, and regular use. 

The success of the project resulted in positive feedback from the client's customers and confidence that the decals would perform as expected throughout their intended use.

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