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How Are Motorcycle Helmets Made? Understanding Thermoplastic Shells

Jul 10, 2024

Advantages and disadvantages of thermoplastic helmet manufacturing and how it compares to other materials.

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We’re diving into the nitty-gritty of helmet safety to keep you informed and safe on the road.


Let’s talk about how motorcycle helmets are made, starting with thermoplastic shells. These shells are typically manufactured using injection molding. Here’s how it works: Molten polymer is injected into a mold that contains both a positive and negative mold at specific temperatures and pressures. The polymer then cures to form the helmet shell, with the space between the molds determining its thickness.




Lighter than composite shells

Lower manufacturing costs and reduced labor due to automated machinery

Uniform shell thickness

Accurate helmet dimensions without additional finishing processes like trimming or grinding




Require thicker shells for adequate impact strength, which can increase weight and cost

Polycarbonate (PC) shells can be challenging to process

Susceptible to damage from organic solvents or lacquers

Less effective shock absorption compared to composite materials


For more details on the advantages and disadvantages of thermoplastic shells, check out Table 1 on our website.


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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