Machine vendible expandable helmet and manufacture of same

A bicycle helmet for fitting over a head of a user, the bicycle helmet comprising:

• a segment of flexible cell structures that form a radial honeycomb matrix between first and second ends, the segment movable between a folded condition where each of the first and second ends of the segment are disposed generally parallel and an expanded condition where the radial honeycomb matrix of the at least one segment is configured to be expanded at least partially over the head of the user and arranged radially relative to the surface of the head of the user;
• a first side frame disposed at the first end of the honeycomb matrix, the first side frame having a first connecting passage;
• a second side frame disposed at the second end of the honeycomb matrix, the second side frame having a second connecting passage;
• a strap assembly having a first strap member coupled to the first and second side frames at the first and second connecting passages, wherein the strap assembly is configured to offset the radial honeycomb matrix away from the head of the user in the expanded use position;
• and
• an upper foam pad supported by the strap assembly, the upper foam pad defining first apertures that receive the first strap member, the upper foam pad having (i) a first section positioned between the first strap member and the radial honeycomb matrix;
• and (ii) a second section configured to be positioned between the first strap member and the head of the user.