What Goes Into A Handcrafted Helmet Shell

A made to order helmet starts long before any material is cut. Measurements are taken, the intended use of the helmet is discussed, and a rider works with the maker to settle on a shell, lining and finish that suit them specifically, rather than picking from fixed stock sizes.

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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.

Anti fog inserts and coatings help in cold or wet conditions, but they are not a substitute for a visor in good condition. Once scratches build up to the point where they catch the light on every ride, it is time to replace rather than keep cleaning around the problem.

A certified helmet carries a label inside the shell showing the standard it meets, along with a homologation number that identifies the specific model tested. This label is worth checking on any helmet, since it confirms the exact helmet in your hands passed the test, not just the range it belongs to.

A helmet that is the right size should feel snug all the way round with no single pressure point, and it should not shift when you turn your head firmly from side to side. A helmet that moves independently of your head on a shake test is not the right fit, regardless of what the size label says.