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Exploring Motorcycle Helmet Inner Shell Components: PP, PE, and Pb Foam Liners

Jul 10, 2024

Understand the Benefits and Drawbacks of PP, PE, and Pb Foam Liners in Helmet Manufacturing


Let’s dive into the manufacturing of motorcycle helmets and explore the inner shell components: PP, PE, and Pb foam liners.


These foam liners, similar to EPS, are molded using conventional molds with hemispherical cores and cavities that extend beyond 180° curvature. This design allows for easy removal of the helmet without distorting the liners (Shuaeib et al. 2002b). During the molding process, holes for retention systems and ventilation are integrated directly into the liners, optimizing their functionality (Gessalin 1984).


Projections on the mold ensure minimal material removal, maintaining liner elasticity and integrity during production. For a detailed breakdown of the advantages and disadvantages of PP, PE, and Pb foam liners, check out Table 4 on our website.




Excellent impact performance, rivaling EPS and PP liners.

Fewer manufacturing constraints compared to EPS.




PE liners are heavier than EPS.

PE foam cannot be recycled for reuse.

PP liners have reduced compression strength at high temperatures (Mlyajlma and Kitahara 1999).


For more content or illustrations, head to our website, or check out our FAQ. To reference our article to your friends, or family, in the Motorcycling/Motorsport community, click the link below or simply copy this URL or bookmark the page for future referencing: Otherwise read our next article about Helmet Laser Scanning Shines the Green Light Significantly Enhancing Your Safety, titled “Helmet Safety: Vital for Motorcycling”


“Our motorcycle safety course in helmet protection”



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