PRODUCTION & QUALITY
HANDCRAFTED IN JAPAN. The name SHOEI has long been synonymous with “premium” in the motorcycle helmet market-a credential that hundreds of loyal men and women in our Japanese factories wear with great pride. The evolution and production of our world-class helmet line is a meticulous process that combines the very latest in technology with consumer feedback, modern testing practices, advanced materials, and nearly 60 years of helmet building experience. Just like the very first SHOEI helmet built by our founder back in 1959, every SHOEI today is still handmade in Japan utilizing a sophisticated process that involves over 50 people for each and every helmet.
SHELL MOLDING
SHOEI’s proprietary AIM (Advanced Integrated Matrix) and AIM+ shell molding technology integrates a multi-ply matrix of hand-laid interwoven layers of fiberglass with organic fibers and resin. Together, these materials combine to maximize strength and elasticity in a strong yet lightweight shell, and each is personally marked by the technician responsible for it to further endorse the quality of every helmet
LASER CUTTING
Robotically controlled lasers give each helmet its final shape by cutting off protrusions created during the shell molding process, as well as creating the openings for eye and ventilation ports. Once this process is complete, all helmets are thoroughly inspected to ensure proper material thickness and weight before moving on to the next phase of manufacturing
PAINTING & GRAPHICS APPLICATION
SHOEI’s intricate painting and graphics application procedures are second to none. Combining handwork with state-of-the-art automation processes to ensure optimal quality, each helmet boasts a premium painted finish and hand-applied decals before being sealed and protected with several quality layers of clearcoat. Each and every SHOEI helmet receives up to five layers of paint before final assembly.
FIT & COMFORT
SHOEI knows that one size does not fit all, which is why we offer an industry-leading number of shell sizes, as well as various liner sizes and cheek pad thicknesses to ensure a customizable fit for each and every rider. Along with extensive research on head shapes and sizes, SHOEI incorporates a mix of exclusive comfort and performance features into the construction of every helmet. Groundbreaking components like our 3D Max-Dry Interior Systems, 3D-shaped center pads to match the contours of a rider’s head, fully removable, washable and replaceable liner systems, multi-layer cheek pads, eyeglass channels, and integrated neck pads accentuate the impeccable comfort packages exclusive only to SHOEI helmets.
FINAL ASSEMBLY
A critical step in the manufacturing process, final helmet assembly is done with care and precision, including the installation of ventilation sliders, shield seals, impact absorbing EPS liners, and comfort interiors. 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 standards guarantee the consistently high quality of a SHOEI.
ACTIVE SAFETY
THE INTERACTION BETWEEN COMFORT AND PROPER FIT
The material and shape of SHOEI’s interior systems are critical factors for the overall wearing comfort and proper fit of the helmet. The wearing comfort covers the effect of the material properties on the skin of the rider. The fit defines how well the helmet sits on the head and stays in place, which is especially noticeable at high speeds. In the past, these two criteria often worked against one another.
OPTIMIZATION OF LINER COVER MATERIALS
The development of new high-performance fabrics allows for greater sweat absorption and dissipation, yielding a proprietary sweat absorbing material that greatly improves rider comfort. These materials (first researched and developed in motocross and road racing where the amount of physical exertion and hence the production of sweat is extremely high) are now production features in the majority of SHOEI’s helmet models.
IMPROVED SAFETY THROUGH LIGHTER HELMETS
Three factors are crucial for the weight of the helmet as perceived by the rider. The actual weight that is felt by wearing the helmet, the felt weight, and the dynamic weight, which is produced by the wind resistance and inertia. The actual weight has a direct influence on the acceleration forces and directly stresses the neck muscles in the event of an accident.
SHOEI’S ADVANCED INTEGRATED MATRIX
AIM and AIM+ Shells Are Made Up of Three Main Features: 1. Fiber-Reinforced Matrix: An outer shell that is made primarily of fiberglass (FRP) is given its shape by a heat-setting plastic resin. 2. The Compound Structure: The AIM and AIM+ shells consist of various layers of reinforcing organic fibers and glass fibers. 3. The Synthetic Resin: A specially modified, unsaturated polyester resin (a so-called heat-setting plastic) is used for the AIM and AIM+ outer shells. This resin acquires the desired strength and elasticity during the heat hardening process.
ADVANTAGE OF THE AIM AND AIM+ OUTER SHELLS
The AIM and AIM+ outer shells from SHOEI offer the best possible impact protection. Through the interaction of the strength and the elasticity of the various materials, the AIM and AIM+ shells have been designed in such a way that the effect of an impact is absorbed and distributed over the largest possible area so that it may be more easily absorbed by the EPS liner.
AERODYNAMICS PERFORMANCE
The stress applied to the neck muscles when riding a motorcycle comes not only from the weight of the helmet itself, but also from wind resistance. For that reason, improving the aerodynamics of a helmet is an extremely important factor in preventing the onset of fatigue. SHOEI’s expert product development team regularly perform tests in our state-of-the-art wind tunnel throughout the entire development process of each and every helmet model to improve shell design and optimize aerodynamic properties.
VENTILATION
SHOEI has developed a dual-layer EPS liner that allows cooling air to travel unrestricted through tunnels created between layers, further enhancing the optimum exchange of warm, humid air with incoming cold, fresh air. Utilizing SHOEI’s in-house wind tunnel to progress ventilation performance, SHOEI is constantly improving the optimal balance between airflow and silence.
NOISE REDUCTION
Utilizing a thicker helmet shell, eliminating ventilation, or using padding that is too tight may reduce the amount of noise experienced, but this is achieved at the expense of safety and comfort. This is not an option for SHOEI. Optimizing shell aerodynamics and liner components allow SHOEI to prevent unwanted road and wind noises without blocking the road’s “informative sounds”.
SHIELD SYSTEM
SHOEI shields protects the rider against wind, dirt, insects and 99% of the sun’s damaging UV rays. Additionally, SHOEI’s 3D injection-molding process ensures a distortion-free view throughout the entire field of vision. Furthermore, the coating on SHOEI shields resists scratches and allows water to bead off the surface more easily.