The Manufacturing Process Of Shoei® Helmet

Forming Process
At SHOEI, all outer shells are made of FRP. During the manufacturing process, a mold is first lined with reinforcing fibers, including fiberglass, and then filled with the plastics. The shell is formed inside a mold by a rubber balloon which presses materials from inside. Every outer shell is hand-made by one of SHOEI's craftsmen. Against the background of SHOEI's production expertise, state-of-the-art technologies are also used for producing newer, more complex shell forms.

Finishing Process
This process not only involves removing superfluous parts of the outer shell like the visor opening and the lower shell edge, but also creating the ventilation system and the mounting holes for the shield. Next to pressing machines, various modern industrial robots like laser robots and automatic cutting machines using conventional blade and water jet technology are also used during the finishing process.In order to further increase the accuracy of helmet production, these machines are for instance used to create mounting holes, in each case to suit the respective part or shape of the part.

Painting Process
Even if a number of manufacturing processes are fully automated, SHOEI now as before continues to rely predominantly on hand-painting as a means of maintaining the high product quality.

Assembly
During this step, the shield, the lower beadings, the impact absorption liner and the comfort padding are assembled by hand in line with detailed instructions. In this way SHOEI ensures that the excellent quality of its products is permanently maintained.