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This is a preview of the HELK Design website. Prices are provisional and do not constitute a commercial offer.
This is a preview of the HELK Design website. Prices are provisional and do not constitute a commercial offer.
We manufacture, we don’t import. In Poland
We are a local company whose whole process — from the scan and the design, through mould building, to the finished part — happens near Kielce, Poland.
Let’s build Polish motoring together.
Where a part has an aero function, we verify how it works in flow analyses. Form goes hand in hand with function.
HELK Design was born from the conviction that the highest-quality and boldest automotive projects can be created in Poland, from the first line of the design to the finished part fitted on the car.
We don’t import ready-made products and we don’t outsource production to external factories. We want real control over every stage of how our parts come to be.
The process starts with a 3D scan of the car, which lets us reproduce its geometry with millimetre precision. Then we move on to CAD design, prototyping and the preparation of masters and production moulds. Only then does the actual production of the carbon fiber parts begin.
The whole process — from the idea, through design and tooling, to production and the final finish — is done in-house in our factory near Kielce.
That is why we are not limited to a catalogue of ready-made products. We can create our own solutions, develop complete aero packages and deliver projects that previously existed only as an idea.
For us “Made in Poland” is not just a label of where a product is made. It is responsibility for the product from start to finish.
Every project starts with a precise 3D scan of the car. It is the foundation of a perfect fit — we work on the real body geometry, not on approximations, keeping an accuracy of up to 0.02 cm.
From that data we prepare the CAD design, taking into account not only the look of the part but also its fit, the way it mounts and its aerodynamic function.
Splitters, diffusers, spoilers and the other parts are designed so that their form also has a technical justification. We analyse the airflow and the effect of the designed solutions on the car’s stability and downforce.
Our team includes people who have worked on aerodynamics for years, so every project is developed both stylistically and technically.
Once the design stage is complete we prepare a master, the base for the actual production mould. We have our own milling facilities, so we can do this stage in-house and keep full control over the geometry of the design.
Mould making is one of the most time-consuming and demanding stages of the whole process. Their quality directly affects the fit, the geometry and the surface of the finished part.
In prepreg technology the moulds go through long temperature cycles above 100°C many times. That is why we make them from materials suited to high temperatures and repeated use.
A properly prepared mould keeps the geometry stable, avoids distortion and gives high repeatability of the parts produced from it.
This is one of the most precise stages of the whole process and it is done entirely by hand. Every layer of prepreg is prepared, cut and laid in the mould by experienced specialists.
Corners, creases and the joins between pieces of material need particular care. Any misplaced fibre, fold or shift can affect both the look and the quality of the finished part.
The layers are laid according to the structural design of the product, and after lamination the part is vacuum-bagged and prepared for curing at a controlled temperature.
After curing, the part is taken out of the mould and moves on to hand finishing.
We precisely finish the edges, the mounting holes and every spot that needs to match the final geometry of the product. At this stage we also check the surface quality and prepare the part for further finishing.
Wherever possible we design and machine the parts to use the car’s original mounting points. That makes fitting faster and simpler, with no unnecessary changes to the factory parts of the car.
Every detail is worked individually so the finished product keeps the right dimensions, looks and the best possible fit before painting.
The last stage of production is painting, polishing and the final finish of the part. This is the process that gives the carbon its depth, the surface its looks and its durability in everyday use.
At HELK Design we use two-component paint systems made for carbon fiber parts, which give high weather resistance and proper protection of the surface.
After painting, every part is carefully polished and prepared for fitting or shipping.
Before it leaves our workshop the product goes through a final quality check carried out independently by two members of the team. We verify both the quality of the finish and the condition of the part before handing it over to the customer.
No product for your model yet? You can create it together with us.
In the Vehicle Development programme we scan the customer’s car as the base for a new product line or a complete package. In return we offer preferential terms and a real say in the styling direction of the project.
The scope can cover single parts, a complete carbon fiber aero package, fibreglass widebody extensions, or an even more extensive restyling of the car.
It is a solution for people who want not only to buy a finished product but to take part in creating something that did not exist before.
We are not limited to catalogue products.
We create unique builds from scratch — from single details and structural parts, through complete aero packages and widebody projects, to unusual builds outside the automotive industry.
Every project is developed individually, with the material, technology and construction chosen for its purpose. We work with both carbon fiber and fibreglass, using our own design and production facilities.
From the first idea, through design and mould making, to the finished part — we can carry out the whole process in-house.
If you have a vision you won’t find in any catalogue, we can help turn it into a finished product.
At HELK Design we make carbon fiber parts in prepreg technology, also known as dry carbon.
Unlike classic and cheaper production methods such as resin infusion or wet layup, the fibre used in prepreg technology comes from the factory pre-impregnated with a precisely measured amount of resin. The material is laid by hand, layer by layer, in a previously prepared mould. It takes remarkable precision and focus, and every part becomes the handiwork of its maker. Once the material is laid in the mould, the part is vacuum-bagged and cured in a controlled temperature cycle.
This gives far better control over the structure of the finished laminate and the fibre-to-resin ratio, and at the same time makes the parts highly resistant to temperature. The result is a material of very high stiffness and strength at low weight, with a surface that allows the finish typical of top-class carbon.
That is why prepreg technology is used in motorsport, in aviation and by the makers of the most advanced cars in the world — no other way of making carbon fiber parts allows all the conditions to be controlled so precisely.
Pagani, Koenigsegg and other brands that build cars without compromise use carbon fiber not just as a styling element. There, carbon is a fully-fledged structural material.
We approach it in exactly the same way.
We don’t want our parts merely to look like premium products. We want the way they are designed, made and finished to truly match the technology they represent.
Resin content
Precisely controlled, giving the best resin-to-fibre ratio
Variable, impossible to control perfectly
Heat resistance
Very high
Variable, depends on the post-cure process
Stiffness and weight
Best strength, lowest weight
Good, depends on the amount of resin
Visual finish
Highest quality and control
Good, more prone to human error
Use
Premium-grade components, supercars
Standard parts
Most of our products are made to order, so the lead time depends on the type of part, the current production load and the chosen finish.
The usual waiting time is around 4–6 weeks. For larger packages, new developments, custom projects or a heavier production load it may be longer.
The current expected lead time for a specific product is given with its offer or confirmed before work starts.
Our products are not ready-made parts brought in from abroad. They are made in our workshop from scratch and go through a multi-stage production process.
Preparing the material, hand-laminating the prepreg, vacuum bagging, temperature cycles lasting many hours, finishing, painting, polishing and the final quality check all take time.
We don’t shorten the process at the expense of quality just to ship a product faster.
Our workshop is in Leszczyny near Kielce, Poland:
HELK Design
ul. Wybranieckich 10
26-008 Leszczyny
This is where the design, production and finishing of the parts and the fitting of our packages take place.
Yes. We also offer professional fitting of our parts and complete packages directly at HELK Design in Leszczyny near Kielce.
That way we can not only make the part but also fit it properly, verify the fit and take care of the final result of the whole build.
For larger packages, splitters, diffusers, spoilers and custom projects we particularly recommend fitting in our workshop.
HELK Design parts are made of carbon fiber in prepreg technology, also known as dry carbon.
The fibre is prepared at the factory with a controlled amount of resin and then cured in a defined temperature cycle. This gives a very good strength and stiffness to weight ratio and high repeatability in production.
It is a different process from the popular parts made with wet carbon or infusion methods.
Yes. We don’t import ready-made parts and we don’t outsource their production to external factories.
From scanning the car and CAD design, through making masters and production moulds, to lamination, finishing and the final finish — the whole process is carried out in Poland, in our workshop near Kielce.
That way we keep control over the product at every stage of its making.
Every new product is designed from a precise 3D scan of a specific car model. This lets us reproduce the real body geometry and take the mounting method and factory mounting points into account already at the design stage.
Bear in mind, however, that cars can differ depending on trim level, market, model year or earlier modifications.
So before buying, always make sure the chosen product is intended exactly for the version of the vehicle you have.
When designing we use the car’s factory mounting points wherever possible. Our aim is to make fitting as simple as possible and to limit unnecessary changes to the vehicle.
For some products, however, additional mounting points may be needed because of their construction, size or function.
The fitting method should always be checked for the specific product.
It depends on the specific product and the experience of the person fitting it.
Although we try to use factory mounting points and keep installation as simple as possible, aero parts need correct positioning and proper fitting.
For larger splitters, diffusers, spoilers and complete packages we recommend fitting by an experienced workshop or directly at HELK Design.
Unless the product description says otherwise, the part goes through the full finishing process and a quality check before shipping.
Carbon parts are painted with two-component paint systems made for carbon fiber, then polished and prepared for handover to the customer.
The scope of delivery and any additional fitting hardware are set out in the description of the specific product.
The paint layer is not only about the look of the product.
Properly done painting brings out the structure and depth of the carbon fiber and at the same time protects its surface from the elements.
That is why we treat painting and the subsequent polishing as an integral part of the production process, not an extra finish.
Carbon fiber is laid by hand, so there may be slight differences in the run or alignment of the weave between individual products.
We take care to keep proper symmetry and looks, especially in the most visible places, but the individual character of the fibre structure is a natural feature of products made from real carbon.
Depending on the product and the stage of the order, a non-standard finish may be possible, e.g. a different type of paint or an individual configuration.
If you want a non-standard variant, contact us before placing the order. We will check whether that configuration is technically possible.
If we don’t have products for your model yet, you can put your car forward for our Vehicle Development programme.
We then use the vehicle as the base for a 3D scan and the development of a new product or a complete package, which may later join the regular HELK Design range.
The car’s owner gets preferential terms and the chance to take part in the making of the project.
Yes. Besides catalogue products we also deliver 1 of 1 projects.
It can be a single part, a complete aero package, a widebody project, a custom carbon fiber component or a build entirely outside our standard range.
The scope, technology, lead time and cost are agreed individually once we have looked at the project.
No. The core of our range is carbon fiber parts made in prepreg technology, but for custom projects we also use other technologies.
For example, extensive widebody projects can be made from fibreglass if that is the better solution for a given construction.
The material is chosen for the purpose of the part, its geometry and the goals of the project.
A large part of HELK Design products is made only after the order is placed, and some builds follow the customer’s individual configuration.
Whether you can withdraw from the contract therefore depends on the nature of the specific order and the applicable law. The detailed rules on returns, products made to the customer’s specification and complaints are set out in the Terms and Conditions and the Delivery and returns section.
Every finished part goes through a final quality check.
Before fitting or shipping, the product is independently verified by two members of our team. We check the workmanship, the surface, the finish and the overall condition of the part.
Only after a positive check is the product prepared for collection or safely packed for transport.
If you want to create a car nobody else will have — start a project. Once we have looked at your request we will get in touch to discuss the details.
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