1) Product Overview
+ Product name: Puzzle Cap – children's protective cap with magnetic surface.
+ Purpose: Protect the head when riding a bicycle or light scooter; at the same time, allow children to arrange, disassemble and assemble magnetic pieces to create unique shapes, stimulate creativity, team coordination and develop fine motor skills.
2) Size & Form
+ Head circumference: 50 – 54 cm (standard for children 6-10 years old).
+ Length (forehead → nape): 24 – 26 cm.
+ Width (ear → ear): 18 – 20 cm.
+ Crown height: 13 – 15 cm.
+ Puzzle surface: +1 mm thicker than normal cone to accommodate thin magnet layer and protective coating.
+ Foam cushion: 1.5 – 2.0 cm thick, many holes Ø 0.8–1.0 cm to ensure ventilation.
+ Target weight: 230 – 260 g (including magnetic layer and magnet).
3) Materials
A. Outer shell
+ Polycarbonate (PC) in-mold or ABS hardshell.
+ Surface covered with thin steel layer/soft magnetic sheet under protective paint to hold magnet, coated with UV-stable coating to prevent yellowing.
B. Magnets & puzzle pieces
+ Magnets: Lightweight Neodymium or ferrite flexible magnets, covered with ABS/TPU plastic to avoid falling or corrosion.
+ Puzzle pieces: Lightweight ABS plastic, rounded edges, printed with non-toxic colors.
C. Impact absorbing layer (Liner)
+ EPS (Expanded Polystyrene) density 40–80 kg/m³, 15–30 mm thick, meeting EN1078 standards.
D. Inner cushion (Comfort pads)
+ CoolMax/bamboo-blend fabric, moisture-absorbing, antibacterial, removable, hand-washable.
E. Retention system
+ Nylon cord 12–15 mm, side-release buckle (polyacetal/nylon).
+ Ratchet dial adjustment ring or simple zipper to adjust the size.
4) Safety & Features
+ Magnets are sealed in plastic and attached with industrial glue + mechanical grooves, do not fall off during play.
+ Pull test ensures that it is below the swallowing threshold for children according to EN71 standards.
+ Magnetic surface is painted with anti-rust paint, no sharp metal.
+ Field of vision tested according to EN1078, ensuring no obstruction by the puzzle pieces.
5) Inspection & Standards
+ Impact test: free fall on flat anvil/kerbstone according to EN1078/TCVN 5756:2015.
+ Retention system & strap strength: test the strength of the rope and buckle.
+ Small parts test: ensure that the puzzle pieces do not exceed the choking risk limit of children's toy standards (EN71-1).
6) Lifespan & Warranty
+ Recommended period: replace after 3-5 years or after a strong impact.
+ Puzzle pieces: average lifespan >3 years, magnetic surface can maintain stable attraction >5 years if stored dry.
+ Warranty: 12 months for helmet shell and magnet system.