What materials are used to make motorcycle helmets and what's the difference. (2024)

Not all helmets are made the same. In a previous article, I discussed the 6 different styles of helmets. Today I’ll be discussing the different materials helmets are made of, and how they protect your head.

All helmets are constructed in the following layers;

  • Rigid outer shell
  • Impact absorbing liner - generally made of EPS (Expanded polystyrene)
  • Comfort liner which also ensures the correct fit of the helmet

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Side cut of a motorcycle helmet

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Break down of what a top of the line Fly Racing off road helmet looks like

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There are 4 basic materials that helmet shells are made of

  • Plastic/ABS
  • Fiberglass
  • Carbon fibre
  • Kevlar/Dyneema/Aramid

There are helmets made of 2 or move of these materials woven together. They are called Composite helmets.

While some helmet materials protect your head better than others, helmets can be quite expensive. Helmet prices range from as little as $70 all the way up to $2500. Not everyone can spend thousands of dollars on a helmet, and not everyone needs to. Keep in mind, no matter what a helmet is constructed of, they all meet a safety standard, and will keep your skull in one piece.

Plastic Based Helmets
There are two basic types of plastic materials used to construct motorcycle helmets - thermoplastic and thermoset resin.

Thermoplastic helmets do not require a hardening agent, and therefore can be melted down and reshaped without chemical decomposition, leading them to be able to be recycled.

Thermoset resin helmets do require a hardening agent.

While plastic helmets do provide good rigidity and flexibility, they are not as strong as their woven counterparts. This leads manufacturers to create plastic helmets larger and heavier. However, plastic helmets come with a lower cost. Upon impact, plastic allows the force of the impact to travel through the helmet easily. This can result in a good brain rattle, and you don’t know what part of your head you may hit.

Composite helmets
Composite fibre helmets are constructed by weaving, or criss-crossing different fibre strands together. Manufacturing composite helmets require more materials and labour, causing them to be more expensive than their plastic counterparts.
Technically, most helmets are composite helmets.

Fiberglass Based Helmets
Fiberglass is inexpensive, lightweight and quite strong - a great combination when creating a motorcycle helmet. The lightest helmets out there will be composed of either Fiberglass or carbon fibre.

The downside to Fiberglass is that it can be quite brittle, shattering upon impact. This is ok when the rider only impacts the ground one, as the impact absorbing liner then does it part in compressing and absorbing the force of the impact. However if the riders head hits the ground again, harm could be caused to the rider. This is why Fiberglass tends to be used in conjunction with other materials to create the safest helmets.

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Raw fiberglass

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Stages of a fiberglass helmet being made

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Carbon Fiber helmets
You’ve probably heard about carbon fiber. It can also be woven into different patterns depending on the desired final look, causing people to add it to nearly everything they can! Often used as apart of additions to cars and motorcycles such as panels and rims, it is also quite useful in the creation of motorcycle helmets.

Carbon Fiber is extremely lightweight (lighter than fiberglass) and strong, as well as quite resistant to pressure and compression. Such helmets are able to withstand impact, and not shatter or crack. Carbon Fiber allows the force of the impact to be spread over a larger area of the helmet, allowing more of the impact absorbing liner to do its job. This is why Carbon Fiber is used in racing helmets.

The one downside to Carbon Fiber is that it is more expensive than the other materials that are used in motorcycle helmets due to higher production and manufacturing costs. Therefore it is often combined with other materials such as fiberglass and kevlar.

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Carbon Fiber sheets

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A Carbon Fiber Skin Shark Spartan GT helmet

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Kevlar/Dyneema/Aramid
Yes, we’re talking about the material they put in bullet proof vests, although they are manufactured differently, so don’t expect your helmet to stop a bullet.

You’ll also see Kevlar in motorcycle jeans, as it doesn’t tear easily and is abrasion resistant, making it perfect for incidents involving a rider sliding down a road.

Kevlar is actually a brand name, like Esky, and was developed by DuPont. Kevlar has an aramid type fiber weave base. This material used in Kevlar helmets is produced with the same weave methods as fiberglass ones, then mixed with a very strong plastic compound.

While Kevlar is quite strong, it does not hold up well against compression. This is why Kevlar is typically added to carbon fiber helmets to increase overall tensile strength, while the carbon fiber is there to counteract Kevlars weak compression rate.

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Kevlar Fibers

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Kevlar Sheets - just like to what is used in Kevlar jeans

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All in all, a composite helmet of Fiberglass, Carbon Fiber and Kevlar is the best makeup of a helmet. You never know what part of your head you may hit, so a helmet that spreads the force of the impact is your best bet. However, even the cheapest helmet is better than no helmet.

Dress for the slide, not the ride.

Ride safe and have a good one!

Got questions? Send me an email at webshop@bikebiz.com.au

Prue Mottram

Published

January 24, 2020

What materials are used to make motorcycle helmets and what's the difference. (11)

What materials are used to make motorcycle helmets and what's the difference. (2024)

FAQs

What materials are used to make motorcycle helmets and what's the difference.? ›

Technically, most helmets are composite helmets. Fiberglass is inexpensive, lightweight and quite strong - a great combination when creating a motorcycle helmet. The lightest helmets out there will be composed of either Fiberglass or carbon fibre.

What materials are used to make motorcycle helmets? ›

From just fiberglass in the 1960s, at least three different materials are now available for the manufacturing of shells, namely pure carbon fiber, composite fibers, and high-resistance thermoplastic. Each of these materials already tends to identify the type of helmet we are dealing with.

What is the best material for a helmet? ›

Overall, carbon fiber is the best material for bike helmets if you are looking for the lightest and strongest possible helmet. If you want the best possible protection, a carbon fiber helmet is the way to go. If you are on a tighter budget, a fiberglass or ABS helmet may be a better option.

What is the best material to make a helmet out of? ›

Carbon Fiber:

Carbon fiber is a strong and lightweight material that's used in the construction of high-end helmets. These helmets are more expensive than others, but they offer the best protection against impact and provide extra comfort.

What is the difference between thermoplastic and polycarbonate helmets? ›

Thermoplastic Shells

The plastic is usually some form of polycarbonate, which isn't the hardest material out there. So, these helmets require more foam padding to meet safety standards. For this reason, thermoplastic helmets are larger and heavier than more advanced lids. However, they are also cheap and easy to make.

What are the best motorcycle helmets made of? ›

Essential features to look for in a motorcycle helmet include a sturdy outer shell made of durable materials such as polycarbonate, fiberglass, or carbon fiber. The inner liner should be made of materials that can absorb impact in case of a crash, such as expanded polystyrene (EPS) foam.

Are carbon fiber motorcycle helmets better? ›

Aesthetically and structurally more advanced, carbon fiber helmets are more durable, crash-resistant and lightweight. So are they worth it? If you have the budget and you're serious about racing, then yes.

What's the difference between polycarbonate and carbon fiber? ›

carbon fibers come as thin sheets that u layout with epoxy to make very light and stiff structures, and as mentioned - don't take hard, sharp blows too nicely... polycarbonate is a flexibale plastic that's quite strong and can take a lot of beating without breaking. 2 different materials groups- composite vs plastic.

How much should I pay for a good motorcycle helmet? ›

On average, a motorcycle helmet will run you around $150 to $200 for something a bit above the cheapest model you can find. There are several reasonable helmets in this price range for the rider who wants a decent helmet but is not willing to pay several hundreds of dollars on it.

What is the average life of a motorcycle helmet? ›

Although there is no "best before date" sticker on a helmet, motorcycle helmets do have a maximum shelf life. Of course this partially depends on the use of the helmet, but that a helmet would last forever is a myth. The average lifespan of a helmet is 5 to 7 years before it needs to be replaced.

What material is a Kevlar helmet made of? ›

One of the most commonly used Aramid fibers is Kevlar (developed by DuPont), which is a proven material for its effectiveness and durability. Known for their high strength-to-weight ratio, they are exceptionally good at absorbing and dispersing impact energy.

Are fiberglass motorcycle helmets safe? ›

Fiberglass is a strong and tested material that can provide effective protection. However, compared to carbon fiber it is more brittle and tends to dissipate the impact energy through disintegration. In most cases this is not a problem; The helmet absorbs impact and the pilot is safe.

Are fiberglass helmets better than polycarbonate? ›

Strong and durable: Fiberglass helmets are typically stronger and more durable than polycarbonate options, often resulting in a longer lifespan. Good impact absorption: Fiberglass helmets excel at distributing impact forces, which can help to reduce the severity of head injuries in the event of a crash.

What material are helmets made out of? ›

Helmets are typically made from a combination of materials including: Polystyrene foam (EPS) - This material is used to absorb impact and distribute the force evenly to protect the head. Fiberglass, carbon fiber or Kevlar - These materials are used to provide strength and durability to the helmet structure.

What are helmets made of now? ›

In conclusion, football helmets are made of polycarbonate for the outer shell, EPS foam for padding, and sometimes TPU cushioning for added protection. These materials work together to absorb impact forces and minimize head injuries.

What were helmets made of? ›

Helmets made from leather, evolved into brass, bronze, steel and then to the complex modern fibers of today. We will be looking at each major period and discussing the evolution, protection offered, and comparisons to those helmets before and after.

What are helmets made of today? ›

These days, most modern helmets from the 1980's onwards use composite materials such as kevlar/aramid. Some popular examples include the American PASGT & ACH, German M92, and Russian 6B7. Alternatively, some helmets use other composite material such as ballistic nylon, basically a very dense plastic.

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