Arai: The Philosophy Behind The Helmets

A Shell Expert demonstrates how he places the multiple fabric components of the shell in the mold. Remember, the process requires that he reach several times into molds that are heated to 200° F. Each helmet has its own series of molds CNC machined in house from steel billet. The process of creating a mold doesn’t stray from Arai’s handcrafting approach, though. Each helmet model’s shell is designed by hand and carved out of clay. Once finalized, the prototype is 3D scanned and optimized for the machining of the molds.