A protective helmet includes: a shell, a headband with an absorbent brow pad, and a suspension. A key is secured to each end of each of the straps of the suspension for insertion into respective key sockets spaced about the periphery of the shell of the protective helmet along its lower edge. Of particular importance to the protective helmet of the present invention, many (if not all) of the keys are molded directly to and around a strap, rather than sewn to the strap. In the method of the present invention, lengths of strap material are positioned in a mold, and plastic is injected into the mold cavity to encapsulate the straps and form the plastic component, e.g., a key for the suspension of the protective helmet. A trimming die is used to trim any webbing scrap between parts or other extraneous materials resulting from the molding of the plastic component to the straps.