The Beginning of Shoei Quality
How and where does SHOEI quality originate (Left Image - Forming of the fibre mats) Are
motorcycle helmets still just crash helmets or are they the upper part of a racer’s
outer skin which is smothered by publicity badges? F.J. Schermer visited the SHOEI factory
in Japan and now knows that they are real works of art, manufactured by hand in an
intricate and caring process.
The primordial basis for quality is
precision. Everything is clean, it would be easier to imagine being in a pharmaceutical
factory than in helmet production. The pre-formed, accurately weighed fiber mats and the
resin are ready to be placed into the steel "baking form".
 (Left Image - Baking of the Helmet Shell) A
slack rubber balloon is then pushed into the form and 120&Mac176;C hot steam is blown
into the balloon blowing it up to five bars. The mats are thus pressed exactly into the
form and actually "baked" for 15 minutes.
SHOEI produces three completely different
helmet shells: for the domestic, American and European markets. This is one of the secrets
of the excellent fit of the helmets.
 (Left Image - Cutting of the
motorcycle helmet shell) After the helmet shells have been cut with water jets and
laser beams, the rest of the production is done by hand. The factory staff check the outer
shells again and again looking for rough spots. The decals are applied in a bath of water,
absolutely no air bubbles should remain.
 (Left Image - Visual and physical inspection of
the motorcycle helmet) The helmet then goes to the Test and Homologation Department
where it undergoes extensive tests according to all worldwide homologation procedures.
Helmets are taken out of production at irregular intervals and tested, tested, tested.
Wind turbulence is simulated in the wind tunnel. The slightest bulges or changes at the
edges have an influence as to how smooth the helmet lies in the wind or how noisy or
silent it is.
 (Left Image - Application of
the motorcycle graphics and decals) After a day’s visit it was established:
typical Japanese quality is produced here by hand. This is why SHOEI helmets can be
classified among the best if not the best in the world.
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