What Goes Into A Handcrafted Helmet Shell

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 handcrafted shells behind our range, visit helmet workshop London.

Getting helmet sizing right starts with a proper head measurement, taken with a soft tape around the largest part of the head, just above the eyebrows and ears. That figure points to a starting size, but it is only a starting point, since head shape varies as much as head size.

Any impact, including a helmet dropped from a moderate height, can compress the inner liner in ways that are not visible from outside. A helmet is designed to absorb one significant impact by sacrificing that inner material, so a helmet involved in a crash should always be replaced, not inspected and reused.

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.

To compare our full face and open face ranges side by side, see helmet workshop London.