SHOEI PRODUCTION & QUALITY ASSURANCE

For all the energy and passion that are invested in the development of a product, the same level of care and due diligence must be achieved during the production process. The following insight explains the individual processes that ultimately results in the unique quality of SHOEI helmets.

SHELL MOLDING
SHOEI exclusively uses fiber-reinforced plastics that offer the best properties for the production of a helmet shell. Thanks to many years of experience and highly specialized employees, SHOEI is in a position to produce helmet shells that are extremely strong and light weight. Each helmet shell is marked personally by the employee who is responsible for it. The employee puts his or her name on the line by endorsing the quality of each and every helmet.

LASER CUTTING
Here the helmet is given its final shape. All the protrusions that area created in manufacturing are cut off. The openings for the shield and ventilation are burnt into the helmet shell with a laser. Finally, the helmet is checked to ensure that it has the correct material thickness and weight.

PAINTING

Even though many production steps have been automated today, it is still critical that some processes are done by hand. SHOEI combines handwork and automation in production to ensure optimal quality.

FINAL ASSEMBLY

The ventilation sliders, shield seals, inner shell, and padding are assembled with great care. Each helmet passes a detailed final inspection before being passed on to the consumer. This strict compliance with the production processes and associated quality control guarantees the consistently high SHOEI quality.

WORKMANSHIP MAKES THE DIFFERENCE

Workmanship plays a significant role in the manufacturing of SHOEI helmets. This is especially clear when we look at the example of the painting.

1. THE PRIMING
After the helmet has been taken from the mold and all protruding parts and openings have been removed by laser, the helmet is given its first priming. Next, each helmet is sanded and polished by hand, producing a flawless surface for the subsequent painting operations. Working on the various helmet shells with their own peculiarities requires a high degree of experience.

2. CHECKING THE PRIMING
The helmet priming is carefully checked for any small blemishes and passed for further painting – but only if the surface is absolutely perfect.

3. THE PAINTING
The quality of a painting operation depends on the quality of its individual painters. It is virtually impossible to apply a high-quality coat of paint by machine, even with the very latest polyurethane paints. For that reason, only specially qualified employees are used in this process.

4. CHECKING THE PAINTING
The paintwork is subjected to close inspection for drips, inclusions, and unevenness.

5. APPLYING THE DESIGN
Elaborate, extremely detailed and spectacular graphics are part of the brand image of a SHOEI helmet. In a very complicated work step, water decals are applied by hand by specially trained workers to the finished painted helmet.

6. PROTECTIVE CLEARCOAT
The last step in the painting process is the application of a clear varnish to the shell to protect the graphics and to give the helmet its unmistakable brilliance.

7. THE FINAL APPLICATION
Before it is passed on for final assembly, the finished paintwork of the helmet is given one last meticulous inspection. Perfection, even in areas that are unnoticeable by the untrained eye, is a must.

NO COMPROMOISE, EVEN FOR INVISIBLE PARTS

QUALITY CONTROL

Each helmet that leaves our factories in Ibaraki and Iwate has first been subjected to intensive quality control.

QUALITY CONTROL IN THE DEVELOPMENT STAGE

The Snell and DOT safety standards play a major role during the development of a helmet. The helmet shell and the shock-absorbing EPS liner are continuously tested for hardness and elasticity and modified as required. This results in a helmet that meets the strict standards that are applied, and still includes all the advantages of the original design.

QUALITY CONTROL DURING PRODUCTION
Strict quality control guidelines at SHOEI are in place during all phases of production, from manufacturing of the outer shell to the point of final assembly. In addition, samples are regularly taken from normal production and tested at the company’s own test facilities. Every year, more than 3,000 helmets are tested to ensure safety, and destroyed in doing so. These test helmets make a major contribution to the overall safety of our products.

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