Shoei manufactures handcrafted motorcycle helmets and visors in Japan with shells made from AIM/AIM+ fibre composite and an EPS core

SHOEI Distribution GmbH

Langenfeld (DE) · Vulaines-sur-Seine (FR) · Milan (IT) · Ibaraki (JP) · Iwate (JP)New on Amplifa

1959Founded (Shoei Kako Co., Ltd., Tokyo)

< 800Employees worldwide (Shoei Group)

5Sites (Europe, Japan)

ca. 1.150–1.700 gHelmet weight depending on model

2011Own wind tunnel in Ibaraki commissioned

About Shoei

Shoei is a Japanese manufacturer of motorcycle helmets, with parent company Shoei Kako Co., Ltd. based in Japan. Since its founding in 1959 in Tokyo, all helmets have been developed and manufactured at the Ibaraki and Iwate plants in Japan; more than 50 employees are involved in the production of a single helmet. Production encompasses the manufacture of helmet shells from AIM and AIM+ fibre composite materials as well as carbon fibre and Kevlar, EPS foam cores, the painting of the shells, injection moulding of the visors from polycarbonate, and predominantly manual assembly. Development and testing take place, among other things, in the company's own wind tunnel in Ibaraki (commissioned in 2011) and in racing with the Shoei Racing Team. SHOEI Distribution GmbH in Langenfeld is the European headquarters of the group, which has fewer than 800 employees worldwide, and distributes helmets, visors and accessories via distributors in more than 40 countries.

Site: Langenfeld
Processes: Shell production of helmet shells, Painting of helmet shells (drying of painted shells), Injection moulding of visors (injection-moulded visor, Z-100), Handcrafted helmet assembly, Testing in the company's own wind tunnel, Quality control, Personal Fitting System (individual helmet fitting), Helmet Registration (service/registration)
Materials: Carbon fibre, Kevlar, EPS (foam core), AIM (Organic Fibre Matrix shell), AIM+ (Organic Fibre Matrix shell), Polycarbonate visor, AIM (Organic Fibre Matrix), AIM+ (Organic Fibre Matrix)
Certificates: Wind tunnel tests (Ibaraki), Quality control in Japanese production
Founded: 1959
Industries: Motorcycle helmet industry, Motorsport, Two-wheeler accessory retail

01
R&D and design
02
Shell production of helmet shells (AIM/AIM+, carbon fibre, Kevlar)
03
EPS core manufacturing
04
Painting and drying of the shells
05
Injection moulding of visors (polycarbonate)
06
Manual assembly (more than 50 employees per helmet)
07
Testing and quality control in the company's own wind tunnel
08
Distribution via European headquarters and distributors

Materials & Processes

AIM

AIM (Organic Fibre Matrix)

Fibre composite shell material for full-face, touring and open-face helmets.

AIM+

AIM+ (Organic Fibre Matrix)

Higher-grade shell variant for sport and off-road helmets such as the X-SPR Pro, Hornet ADV and VFX-WR.

Carbon Fibre

Lightweight material for helmet shells; in 1976 Shoei introduced the world's first carbon fibre helmet with the GR-Z.

KEV

Kevlar

Aramid fibre used to reinforce fibre composite shells.

EPS

EPS Foam Core

Energy-absorbing inner core, made in two-part form since the X-8SP (1993).

Polycarbonate (Visor)

Material of the injection-moulded visors and sun visors.

Sites

Langenfeld

European headquarters / distribution (SHOEI Distribution GmbH)

Vulaines-sur-Seine

Distribution (SHOEI EUROPE Distribution SARL)

Milan

Distribution (SHOEI ITALIA Srl)

Ibaraki

Production plant with wind tunnel, R&D

Materials: AIM, AIM+, Carbon Fibre, Kevlar, EPS, Polycarbonate

Wind tunnel (2011)
Shell production
Paint shop
Assembly

Iwate

Production plant (built 1989)

Shell production
Assembly

Products

**X-SPR Pro Full-Face Helmet**AIM+ shell, hand-assembled · Motorsport/Street

**NXR2 Full-Face Helmet**AIM shell · ECE 22-06

**GT-Air 3 SMART**AIM shell, optional visor HUD · Touring

**GT-Air 3 with Sun Visor**AIM shell, QSV-2 · Touring

**Glamster 06**AIM shell, ca. 1.300 g · Retro/Street

**Neotec 3 Flip-Up Helmet**AIM shell, Micro Ratchet · Touring

**J·O2 Open-Face Helmet**AIM shell, ca. 1.150 g · City/Classic

**J-Cruise 3 Jet Helmet**AIM shell, ca. 1.400 g · Touring

**Hornet ADV 06**AIM+ shell · Adventure/Offroad

**VFX-WR 06 Motocross Helmet**AIM+ shell, M.E.D.S. · MX/Offroad

**X-Spirit 3 Racing Helmet**AIM+ shell · Motorsport

Inside the production

Industries

Motorcycle helmet industryMotorsportTwo-wheeler accessory retail

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
Shell production of helmet shellsCasting	–	–	–	–	AIM, AIM+, Carbon Fibre, Kevlar
Painting of helmet shells (drying of painted shells)Surface	–	–	–	–	–
Injection moulding of visors (injection-moulded visor, Z-100)Plastics	–	–	–	–	Plastics
Handcrafted helmet assemblyAssembly	–	–	–	–	–
Testing in the company's own wind tunnelTesting	–	–	–	–	–
Quality controlTesting	–	–	–	–	–

3 Anlagen & Maschinen

Machine	Manufacturer / model	Quantity	Working area	Year built	Site
Wind tunnel	Shoei	1	–	2011	Ibaraki, Japan
Helmet shell/assembly production plant	Shoei Kako Co., Ltd.	1	–	–	Ibaraki, Japan
Production plant	Shoei	1	–	1989	Iwate, Japan

Additional services

Personal Fitting System (individual helmet fitting)Helmet Registration (service/registration)Spare parts & accessories (visors, Transitions self-tinting visor)Merchandise

Reference customers

Marc Márquez (MotoGP)Fabio Di Giannantonio (Gresini Racing Team, MotoGP)Toprak Razgatlıoğlu (World Superbike)Jeremy Seewer (MXGP)

Quality

Every helmet undergoes quality control and testing, including tests in the company's own wind tunnel in Ibaraki (commissioned in 2011). Testing is also carried out in racing with the Shoei Racing Team (including MotoGP, World Superbike, MXGP).

Evidence	Langenfeld
Wind tunnel tests (Ibaraki)
Quality control in Japanese production