What Goes Into A Handcrafted Helmet Shell

The trade off is scale. A workshop like this will never produce helmets as fast as a large factory, and that is treated as acceptable, since the aim is a considered, well finished helmet rather than the fastest one to market.

To compare our full face and open face ranges side by side, see Hedon.

The result takes longer to arrive than an off the shelf helmet, and that is by design. A made to order piece is fitted, finished and checked individually before it ships.

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.

None of this needs to be bought at once. Building a complete kit over time, prioritising the areas most exposed in a typical fall, is a realistic way to get there.

Getting helmet sizing right starts with a proper head measurement, taken with a soft tape around the largest part of the head, just above the eyebrows and ears. That figure points to a starting size, but it is only a starting point, since head shape varies as much as head size.