Why the world’s best riders trust Shoei

Just for a moment pretend you’re Marc Marquez, hurtling into a bend on your favourite MotoGP circuit, and you’re quietly pondering your safety gear, like the Shoei helmet strapped to your head.

Or, if you prefer, you’re Malcolm Stewart, about to tackle a triple in the latest MXGP round, at a pace that defies both physics and logic.

In either case, you really don’t want to be fretting over the quality of your equipment. Which is why they stick with Shoei. How come? Behind the famous logo is a depth of knowledge and experience that goes back over seven decades.

When you look at the company’s premium equipment, there is an extraordinary process of development, design and manufacturing that happens at the company’s two facilities in Japan. It’s unlike any other in that it combines up-to-the-minute tech such as robotics with an incredible level of hands-on finishing.

Whether you pick up premium race gear such as X-SPR road race helmets, the VFX-WR06 off-road models, or the more general-purpose road models such as GT-AIR 3, NEOTEC 3, NXR2 and even the new GLAMSTER 06 retro design, you’re looking at the product of an astonishing process.

Just as a quick indicator, that helmet you’re holding represents a 26-step production process that goes through 50 sets of hands and undergoes an 11-step formal checking process, in addition to the inspection by the individual who worked on it.

And then, just to be sure, examples of each model are randomly pulled from stock and destruction-tested to ensure they’re meeting expectations.

Hundreds of hours of design and concept work goes into each model. As is expected in cutting-edge industries, much of the early work is done with computer-rendered 3D versions before someone goes to the trouble of making a design mock-up to see what it will look like in real life.

The result is then test-built and undergoes a challenging process where it’s trialed in the real world, in a wind tunnel (with real and robotic riders), and of course in a lab that checks its performance in several crash scenarios.

Not only are the testers looking for something that survives the punishment, but spreads forces over the greatest possible area in a way that dissipates the energy and protects the rider.

As the concept is refined, materials are fine-tuned in an effort to cut wind-resistance (in part to ease neck strain), reduce noise and yet provide good ventilation. They’re all things that make a difference to how the helmet feels, and how well you shape up over a long stint in the saddle.

When you look at what the developers and designers at Shoei are doing, you soon realise they’re often working with contradictory factors to find the best possible balance. Think of it as looking for the finer things in a ride.

For example, the shell needs to be of a reasonable thickness to do its main job of protecting you, but you want it to be as light as humanly possible. When you look at the progress of Shoei helmets over the years, you’ll soon see there are constant and often incremental gains in this area. So the premium model you might have bought a decade ago will have been superseded in very real and measurable terms.

Here’s another one for you: ventilation. Yes, you want great airflow, but you don’t want the wind to (literally!) whistle through the shell. That’s where access to assets such as a wind tunnel and experienced test-riders pays huge dividends.

And while we’re trying to keep the noise to a minimum, you still want to hear what’s going on around you – again, it’s quite a juggling act to get this right.

Of course, we all need to see. Even in this area, Shoei goes the extra mile to make sure you get the best possible service from the helmet. All the company’s visor materials are tested for and meet critical protection criteria.

But it’s not just about protection from the wind and the bugs, it’s about providing 99 per cent UV protection in every example. Plus, Shoei employs a 3D injection moulding process to ensure your entire field of vision is free from distortion.

A final touch to protect your investment: there is a scratch-resistant coating that encourages water to bead for clearer vision in the rain.

As you can see, when you look into some of the details, it becomes clear that Shoei backs up its talk about producing premium helmets with real-world action.

Let’s take a closer look at what goes into the helmet itself, shall we?

The process begins with the hand-laying of the complex matrix of mediums such as fiberglass, organic materials and resin in a process dubbed AIM – Advanced Integrated Matrix. Each technician who does the shell (which are made in several sizes for the best fit) personally signs the product before it moves on.

The AIM and AIM+ systems have one key mission: to ensure the effect of an impact is spread over the widest possible area so that it is more easily absorbed by the EPS liner.

Now the humans move aside for a moment, so a robotically controlled laser cuts the shell to its final shape.

It’s then passed over to the paint shop, which uses a mix of automation and human intervention to produce a multi-layer finish. Then it’s over to the folk who hand-apply the decals and artwork.

By now we’re heading for final assembly, which includes the EPS liner, various seals, plus the all-important hardware for ventilation controls and visor systems.

Fitting out the interior is very much a hands-on process. It employs an incredible range of materials to provide protection and keep the lining fresh and dry. There is a whole system in place for the latter, called 3D Max-Dry Interior Systems. Plus, much of the padding can be swapped out to subtly change the final shape and fit of the helmet to your individual needs.

As you can see, there is a whole lot more involved than first meets the eye!

Perhaps the best aspect of the SHOEI range is you can access this level of experience and quality in a whole range of riding ‘flavours’, where you’re bound to find something that best suits your particular needs. Some of the popular options include:

MotoGP-style performance used by the likes of Marc Marquez and Fabio Di Giannantonio. Tested for stability at speeds exceeding 350km/h. FIM homologation means you can use it on the track. Includes a sophisticated ventilation system and has been designed so even the cheek pads produce downforce. This is the ultimate track weapon.

Premium MXGP-style helmet as used and tested by legends such as Jeremy Seewer and Malcolm Stewart. Features the innovative Motion Energy Distribution System (MEDS) liner to reduce rotational acceleration energy in the event of an accident.

Ultra-flexible sportstouring road helmet with dual visors, ready to integrate the Shoei Comlink system; a Bluetooth/Mesh comms system created in partnership with SENA that is built into the helmet to keep the external lines and aerodynamics unchanged.

Innovative flip-up sports-touring design with the dual visor system that includes the QSV-2 inner sun visor, also able to integrate with Comlink.

Open-face touring helmet for urban cruising and long touring. Includes internal sun visor, excellent ventilation to pull hot air out of the helmet, Comlink integration and beveled-edge visor to ensure stability at speed and prevent wind from entering the helmet.

A new generation of the popular general-purpose road helmet with upgraded aerodynamics and ventilation. Available with an external SENA comms system specifically made for the lines of the NXR2, creating a clean and streamlined finish.

A brand-new model! Classic retro looks incorporating up-to-the-minute technology to provide great comfort, safety and performance.

Rest assured that when you purchase any Shoei helmet, you’ll be riding with a level of safety that can only come from a helmet manufacturer with decades of experience and an unwavering commitment to providing the best in technology, comfort, style, and protection. Why would you trust anyone else?

For more information, check out the full range at the Australian Shoei website.