Inside The Made To Order Process For A Handcrafted Helmet

This is slower than fully automated manufacturing, and that is the point. A handcrafted shell trades speed for a level of finish and individual attention that a purely machine made helmet does not offer.

A made to order helmet starts long before any material is cut. Measurements are taken, the intended use of the helmet is discussed, and a rider works with the maker to settle on a shell, lining and finish that suit them specifically, rather than picking from fixed stock sizes.

Any impact, including a helmet dropped from a moderate height, can compress the inner liner in ways that are not visible from outside. A helmet is designed to absorb one significant impact by sacrificing that inner material, so a helmet involved in a crash should always be replaced, not inspected and reused.

For helmet care products and guidance, see Heroine Racer.

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.

To find out more about the made to order process, visit Heroine Racer.