Shoei Helmet Manufacturing Process

Shoei Helmet AIM + Carbon Manufacturing

Product Development:

Product development plays an important role in the optimization of wearing comfort, which according to Shoei is a crucial component of a rider's ability to concentrate. We hope you will gain a deeper understanding of the Shoei process.

Manufacturing Process:

Shoei helmets are constructed using AIM or Advanced Integrated Matrix, technology. AIM is a process whereby organic fibers are combined with fiberglass and hyper performance fibers to form the helmet's outer shell. This results in an outer shell that provides an ideal level of impact absorption, sufficient elasticity, light weight and a high degree of rigidity.

Forming Process:

Shoei helmets' outer shells are made of fiber reinforced plastic (FRP). During the manufacturing process, a mold is first lined with reinforcing fibers, including fiberglass, and then filled with polymer. A steam-inflated rubber balloon is then inflated inside the mold which embeds the fibers in the polymer to form the outer shell. Every outer shell is hand made by one of Shoei's skilled craftsmen.

Finishing Process:

This process not only involves removing superfluous parts of the outer shell, such as the visor opening and the lower shell edge, but also creating the ventilation system and the mounting holes for the visor. Using laser robots and automatic conventional blade and water jet cutting machines, Shoei craftsman are able to finish the outer shell and prepare the helmets for the next step in the manufacturing process.

Painting Process:

Shoei helmets are clearly the most comfortable best made helmets in the world. In addition to that however, Shoei helmets also enjoy an excellent reputation for their paintwork and artwork. The painting process is very intricate; requiring many hours of painstaking work by Shoei's highly trained team of skilled technicians.

1. Base Coat: The base coast is evenly applied to the untreated outer shell, sealing it against the elements

2. Polishing: Once covered with base coat, the outer shell is then carefully polished with very fine sandpaper. This time intensive process ensures that the paint adheres properly to the base coat and prevents the paint from peeling off.

3. Optical Shell Examination: The polished shell is subjected to a thorough visual inspection to make sure that each shell is perfect and ready for the next step.

4. Painting: The quality of the paintwork is ensured by its layered application. If the layering process is not perfect, however, the entire paint job will be sub standard, even if top quality paint is used. For this reason, all paint application is done by hand to ensure complete coverage.

5. Quality Control: Upon completing the paint process, each helmet undergoes a thorough examination. If the paint application is not perfect, then the entire helmet is sanded down and the process is started all over again. This commitment to quality ensures long term durability and the superb look of the paintwork.

6. Transfers: Using an extreme amount of patience and skill, Shoei's technicians apply the graphic decals tot he shell using water.

7. Clear Varnish: A clear acrylic layer is applied by hand to protect the paintwork. This process is repeated several times in order to produce the helmet's ultra gloss finish.

8. Final Inspection: Each shell is subjected to one final thorough examination. If it passes this rigorous inspection, the shell is ready for assembly.

Assembly:

During this step, the visor, the lower beadings, the liner, and the comfort liner are assembled by hand in line with detailed instructions. This painstaking process ensures that the excellent quality of Sheoi's products is permanently maintained.

Shoei AIM (Advanced Integrated Matrix) The AIM shell is composite that contains a thermoset polymer plus various layers of reinforcing organic fibers and fiberglass. The organic fibers of low specific gravity are combined with fiberglass to create the outer shell. When compared to other helmets that are made of only fiberglass, Shoei's AIM helmets provide greater rigidity at a fraction of the weight.

Shoei has taken their AIM helmets to the next level, as their engineers have introduced a new hyper performance fiber that is so strong that it can only be cut with a laser, yet it is lighter than a piece of cotton fabric. This new fiber is used in Shoei's new AIM + shells that are used to make the new X-Eleven and RF-1000 model motorcycle helmets.

Once the shells have formed, they are sealed using a specially adapted unsaturated polyester resin, or thermoplastic. During the thermosetting stage the resin forms a three dimensional 3D molecular structure that ensures both rigidity and elasticity. This resin is also highly corrosion resistant, giving the helmet unprecedented protection from external elements.