Safety is the core of every motorcycle helmet. As a professional helmet manufacturer supplying global distributors and brands, we implement systematic quality control covering every production stage, from raw material incoming inspection to finished product delivery. Every procedure follows standardized rules to ensure all helmets satisfy international safety certifications including ECE 22.06 and DOT. Below we take you through our complete quality control workflow.
Quality control starts before production begins. All raw materials, including ABS plastic, carbon fiber fabric, paint, inner EPS foam, liners and visors, are tested upon arrival. Our QC team checks material density, impact resistance, environmental protection performance and dimensional consistency. Unqualified raw materials will be rejected directly and cannot enter the production workshop. Stable raw material quality lays a solid foundation for finished helmet safety.
During shell injection molding, operators conduct regular sampling checks on shell thickness, surface integrity and shape accuracy. Once a new mold is put into use or production parameters are adjusted, the quality team carries out a first article inspection. Only after confirming no deformation, bubbles or cracks can mass production start. This step avoids large batches of defective shells.
After shell molding, helmets go through surface treatment, primer and topcoat spraying. QC staff inspect each shell for paint unevenness, orange peel, scratches, dust spots and color difference. For customized graphic helmets, we carefully verify printing position, pattern clarity and adhesion. Any flawed surface products will be sent back for rework to guarantee consistent appearance for bulk orders.
Impact-absorbing EPS liner is critical to helmet safety. Workers precisely assemble EPS inside the outer shell. The QC team randomly inspects EPS bonding tightness and assembly clearance. We also check cheek pads, chin straps, buckles and inner liners. All accessories must be firmly installed without looseness, ensuring comfortable wearing and reliable protection.
Random sampling impact testing is the most vital part of our quality control system. Selected finished helmets are sent to the laboratory for impact absorption tests simulating real crashes. Sampling frequency follows international certification requirements. If any sample fails the test, the corresponding production batch will be suspended for full re-inspection.
Qualified helmets receive a final full inspection. QC personnel double-check appearance, labels, certification marks and accessory completeness. Before shipment, we confirm packaging firmness to prevent scratches or damage during long-distance ocean and land transportation.
Many overseas distributors face risks such as unqualified goods, customs detention and customer complaints caused by poor helmet quality. Our multi-layer quality control system effectively reduces these risks:
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