What Goes Into A Handcrafted Helmet Shell

To see the handcrafted shells behind our range, visit ECE 22.06 certified helmet.

Once the shell is formed and cured, it moves through finishing: sanding, painting or leather trimming, and fitting the internal padding and retention system. Every stage is checked before the next begins, since a fault caught early is far cheaper to fix than one found at the end.

Most manufacturers recommend replacing a motorcycle helmet every five to seven years even without a crash, since the internal materials that absorb impact degrade slowly with heat, sweat and UV exposure. The shell can look fine while the protective layer underneath has already lost some of its effectiveness.

A handcrafted helmet shell starts with a base material, commonly fibreglass or a composite blend, layered and shaped by hand rather than produced purely by mould and machine. Each layer adds strength, and the shaping stage is where a lot of the time in production actually goes.

To see the certification behind our own range, visit ECE 22.06 certified helmet.

To compare our full face and open face ranges side by side, see ECE 22.06 certified helmet.