Arai Hand Made

1. The construction of the outer shell is the start of the helmet manufacturing

process. Super-Fiber strings form the base of the shell. Besides Super-Fiber,

other materials such as Kevlar®, Nylon and carbon fiber are used on selected shells.

2. Super-Fiber strings are chopped and then sprayed on a metal

mesh mold in a chamber,and shaped into what looks like a straw hat.

3. This “straw hat” together with additional Super-Fiber and other fiber materials

are put in a molding device, and then resin is poured into the mold. The molding

device is then closed tightly with a lid that has a balloon underneath it. The balloon

is inflated and the molding device is heated to form an outer shell.A) Molding device

and helmet molding B) Layers of fiberglass C) Pouring resin in D) Closed molding

device lid, with balloon underneath E) Inflating the balloon

3. This “straw hat” together with additional Super-Fiber and other fiber

materials are put in a molding device, and then resin is poured into the mold.

The molding device is then closed tightly with a lid that has a balloon underneath it.

The balloon is inflated and the molding device is heated to form an outer shell.

A) Molding device and helmet molding B) Layers of fiberglass C) Pouring resin in

D) Closed molding device lid, with balloon underneath E) Inflating the balloon

5. The visor opening, chin vent and other vent holes are cut out by a laser-cutting robot.

6. Every shell is then carefully inspected for thickness, weight and structural

correctness. Then it is sent to another inspection department for final inspection.

Each outer shell is therefore inspected twice.

7. Passed shells are then undercoated and sanded. This process is repeated twice,

to get a fine, even surface for a smooth finishing coat.

8. Decals are applied onto the shells for models that come with graphics.

9. Holes for visor, chinstrap and ventilation ducts are drilled, and then the shells

are trimmed with edge rubbers.

10. The shock absorbing inner shell Is installed into the outer shell.

11. Visor, ventilation ducts and other parts are mounted, making sure each part

fits and functions properly.

12. After polishing and labelling each helmet is inspected carefully, and then

proceeds to packaging.