The Basic Construction of a Motorcycle Helmet

A motorcycle helmet is a useful and helpful protective gear for a motorcyclist. A rider must have this safety equipment to guarantee his well-being on the road. It is advisable that you purchase a helmet that is of quality. And before you acquire a motorcycle helmet, you must have knowledge on how a motorcycle helmet is constructed.

Know your Motorcycle Helmet

It is important that you know the information of what motorcycle helmet you are going to buy. These include the construction components of the motorcycle helmet, from what materials it is made of, and how the motorcycle helmet is made.

  • Helmet Materials

There are different materials that are used for making a motorcycle helmet. These materials are plastics, carbon fiber, fiberglass, epoxy resin, thermoplastic, polycarbonate, composite, and Kevlar, among others. The modern helmets are made from plastics. And the most durable and the most expensive material used for motorcycle helmet is the carbon fiber. The interior parts of the motorcycle helmet have foams and fabric. These are designed for protection and comfort.

It is recommended that you choose a motorcycle helmet that is made from a light material such as the carbon fiber, polycarbonate, composite, carbon or Kevlar. A lightweight motorcycle helmet can provide safety and ease. A heavyweight helmet will create pressure on your neck and you will feel uncomfortable. This can affect your driving that may result to an accident. The ideal weight of a motorcycle helmet is 1200 to 1340 grams.

  • The Basic Construction Components of a

    Motorcycle Helmet

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Photo Credit:

The motorcycle helmet has 3 layers namely the shell, EPS lining, and the inner lining. The first two layers are for protection and the inner lining is for comfort. They are described below:

  1. The Shell

The outer shell of the motorcycle helmet can be made of fiber, plastic, carbon fiber, Kevlar, or the tri-composite of the three. The shell is designed for durability. Its primary goal is to protect your head in any event of crash or impact. It also protects the EPS lining.

    2. EPS Lining

The next protective layer of the helmet that is located beneath the helmet shell is the EPS or the Expanded Polystyrene Foam lining. This lining absorbs energy in case there is an impact. It redistributes the impact on the bigger area thus lessens the impact on the skull. It also limits the full force on the skull and ventilates the head.

    3. Inner Lining

The inner lining provides comfort. It consists of a lining for the upper head area and the two cheek pads. Some of the inner linings of the modern helmets are removable and washable. Some have fabrics and anti-allergenic properties.

How a Motorcycle is Made

The procedures on how to make a motorcycle helmet are as follows:

  • The Manufacturing of the EPS Helmet Liner

The EPS is placed in a huge container that is filled with polystyrene. Then the polystyrene is blown or expanded in the manufacturing facility to convert to EPS. They are manufactured in various densities and merged together in the molding process. The EPS that is of quality is engineered for each various head size. The EPS liner has its own mold that is planned in Computer Aided Design (CAD) system and manufactured at Computer Aided Manufacturing. The blown EPS are stored in a climate controlled area until they are molded into proper shape.

  • The Making of Helmet Shell

Photo Credit:

Photo Credit:

The helmet shell mold is also planned using CAD and the CAM. The helmet shell mold is custom made based on the helmet size and design. The shell mold has a life span. There must be a new mold every time a new helmet design is created. Each helmet shell is molded for about 60 seconds. The molding machine involuntarily releases the helmet shell mold. Afterward, the shell is prepared for sanding and paint or decal application.

  • Sanding, Painting or Decals Stage

Once the helmets shells were done, they are now ready for sanding. This allows the paint to stick on the surface of the shell properly. Once they are sanded, the helmet shell will be directed to the decal room or the paint room. Then the helmets are deposited to the clear coat area. After having clear coat finish, the helmets are ready for the final assembly. The internal visors, face shield, vent cover, chin guard, liners and other parts of the helmet are installed. Each helmet manufacturing process is examined by the operator for quality.

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