FEATURE
Studio for the finishing touches, something done by hand, minus the logos, which were once done by hand, but has since been automated. Otherwise, straps, padding, and final quality control are done on a production line. Tim Wood, from Echelon Cycles, another retailer invited on the trip, said, “A product is so much easier to sell when you’ve seen it designed, developed, produced, and marketed. I wasn’t fully aware of the helmet safety standards, taking the viewpoint that all helmets exceeded a fairly basic set of standards. Having been on the visit, I’m now enlightened and can talk to consumers in more detail. It’s also good to know that a lot of the ABUS road range is produced in Italy, whereas most of the competition is manufactured in the Far East.
Seeing a lot of the manufacturing process, from screen printing the shell, through putting the individual components of the helmet into the mould, before injecting the EPS in, gives you plenty to talk about. It also shows the time involved and helps justify the cost.”
12 | June 2025
The Future of “Made in Italy” All the back and forth between different factories and facilities is a problem. Not only does it cost time, but having things spread out makes things such as quality control, something they are very strict on, a challenge for ABUS. The solution? Bring everything under one roof. And that’s the plan. By next year, ABUS hope to build their own facility, bringing Maxi Studio, production line, EPS production and testing into one. They recently purchased some land, and construction is due to begin soon.
This move also means an increase in production capacity with a view to doing things in a more sustainable way. ABUS have some exciting plans in the pipeline, with the new plant amongst them. This move cements their dedication to high-quality production and means we may see more than just road helmets produced in Italy in the future. Want to visit? ABUS host an open house in both Italy and Germany and take people on a regular basis. Contact ABUS UK for more information.
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