Our factory is located in Buenos Aires, Argentina. Here we design and assemble all Falcon Polo helmets.
The manufacturing process of our most reliable polo helmets has been continuously improved since Floriano Falcon himself made his first polo helmet in 1985.
Today we produce approximately 2,000 polo helmets a year to protect riders around the world, adults and children of all genders.
A polo helmet consists of four main layers of protection. Each part of the manufacturing process is carried out by people trained in our factory, using only materials approved by us and by international standards. Outsourced parts are also subject to international certifications.
The main layers of protection are:
- Outer shell (fiberglass or carbon fiber)
- Inner shell (EPS or EPP)
- The internal pad
- The harness restraint
Outer shell
This is the hardest part of the hull and, therefore, the one that contributes the most weight. It is intended to withstand the initial impact energy, and part of that process is for it to break, but not too much before the inner shell acts.
The material is fiberglass or carbon fiber, with a resin finish. First the complete piece is made and then it is perfected, giving it the final look before painting or upholstering it with fabric or leather. It is even perforated for ventilation and harness attachment.
The matrix we use at Falcon Polo is the one that, since its inception, gave the style to the polo helmet of today. However, given the demands of the standards, they are updated to continue to offer protection while maintaining the style preferred by polo players.
Painted shells
Many Falcon Polo helmet models have a painted shell. This avoids the cost of external upholstery and provides a distinctive and more customizable style by allowing the user to use stickers.
The painting process is manual and the finish is smooth with a glossy or matte appearance. In terms of protection, tests indicate that the painted helmet has less friction than the upholstered helmet, allowing a higher degree of impact dissipation.
Upholstery
The upholstery or cover that covers the outer shell is made by hand, using a specific fabric or leather to withstand wear. All Falcon Polo seams are made to very fine tolerances. The final quality can be seen (and compared) with the naked eye.
The leather we use is eco-leather, as it adapts to the shape of the hull, resists seams and is also lighter. It is very attractive to look at, although the negative aspect is that it tends to maintain a higher temperature.
Inner shell
The inner layer of the helmet is of vital importance to protect your head in the event of a fall, as it is the part intended to absorb and dissipate the energy of the impact.
The material we use at Falcon Polo is EPS or EPP, composed of microspheres that act like bubble wrap for the head. These burst on impact to absorb and dissipate the shock. Both materials have similar characteristics, but EPP is designed to withstand multiple impacts at the same point.
In our factory we create the tooling and acquire the material from those suppliers that have the corresponding certifications.
Internal pad
The inner shell has a layer that offers comfort by reducing friction with additional padding. This layer does not directly offer protection, but indirectly contributes to the fit that is required for the helmet to work properly. The material used is the same as in other disciplines such as horse riding, cycling, skateboarding, etc.
Fixing harness
The harness is another important part of the protection. Its function is to hold the helmet in place in the event of a fall or sudden movement. The harness is attached with rivets to the outer shell at different points, preventing the helmet from sliding forward or backward. The material used is antibacterial and irritation resistant.
Currently, at Falcon Polo we use harnesses with certified material, with greater comfort and durability.
Design and testing
Before a new helmet model reaches the production line, it undergoes a design and testing process. This process involves our own staff as well as independent external safety standards testing companies. The research and development process for a helmet takes up to six months.
Quality
Falcon Polo is the oldest factory of high quality polo helmets in Argentina (born as Falcon Helmets). Nowadays, the manufacturing process has been largely industrialized, which allows a high production speed, although the finishing process is still handmade, always respecting the rules imposed by international standards.