Motorcycle
Full-face, open-face and other motorcycle helmet shell concepts.
OEM HELMET SHELL MANUFACTURING
Custom Carbon Fiber Helmet Shells
Engineering-led shell development for helmet brands and product developers—from customer samples and CAD models to tooling and molded carbon fiber shells.
CUSTOM DESIGNS · NOT OFF-THE-SHELF STOCK
APPLICATIONS
One manufacturing partner. Many helmet categories.
We support the development of customer-specific shell designs for a range of helmet applications. Application suitability and testing are assessed for each project.
Motorsport
Carbon fiber racing helmet shells for customer-defined performance projects.
Ski & Snowboard
Custom shell development for winter-sport helmet applications.
Mountain Bike / Downhill
Shell concepts for mountain bike and downhill helmet designs.
Equestrian
Custom carbon fiber shells for equestrian helmet applications.
Other Applications
Specialized sports and protective headgear projects are reviewed individually.
REAL PRODUCT IMAGES · OEM PROJECT REFERENCE
Explore our custom carbon fiber helmet shell gallery.
View different shell forms and carbon fiber surface appearances from our photo collection. These are reference examples, not off-the-shelf products. Final design, use and certification requirements are evaluated per customer project.
Motorcycle & RoadRacing & PerformanceSki & SnowboardMountain Bike / DownhillEquestrian & SpecializedCustom Finishes & Shapes
Motorcycle & Road
Motorcycle helmet-shell developments, including open-face and full-face geometries
Racing & Performance
Performance-oriented and full-face shell shapes for customer-led development
Ski & Snowboard
Selected compact, ventilated and winter-sport-inspired shell forms; final suitability is design-specific
Mountain Bike / Downhill
Selected larger-coverage and peaked helmet-shell geometries
Equestrian & Specialized
Rounded and brimmed shell concepts; application requirements are assessed for every project
Custom Finishes & Shapes
Examples of material appearances, colors and customer-defined shell geometry
CUSTOM DEVELOPMENT
Based on your sample, drawing or 3D design.
Every custom helmet shell begins with the customer's requirements. Our services can include reverse engineering from physical samples, 3D design development, design adjustments, mold manufacturing and carbon fiber shell production.
Tooling arrangements, materials, layup, thickness and finish are discussed for each project. We do not assume that the same construction works for every helmet type.
- Reverse engineering & 3D development
- Customer-approved CAD before tooling
- Custom molds & composite shell production
- Sample review before batch manufacturing
SHELL DEVELOPMENT
Inside the manufacturing process.
Compression molding is a principal process for our custom helmet shell projects.
Engineering & Tooling
From design review to molds developed for the agreed shell geometry.
Manufacturing
Carbon fiber materials are prepared and molded according to the selected process.
Finishing & Review
Post-molding operations and quality inspections prepare shells for customer evaluation.
PROJECT FAQ
Common questions from helmet brands.
Do you sell ready-made helmet shells?+
JOHHAR focuses on custom OEM manufacturing. Availability of any existing tooling or shared designs must be discussed for the specific project.
What do you need to evaluate a project?+
A 3D model, 2D drawing or physical sample is the best starting point. Please also share intended application, requirements and estimated quantity.
Can you develop a shell from a sample?+
Reverse engineering from a physical sample can be discussed. Any design changes and tooling begin after technical evaluation and agreement.
Are your shells FIA, Snell, ECE or other standards certified?+
Shell manufacturing alone does not establish final helmet certification. Final assembled-helmet testing and certification responsibilities are agreed for each project.
LET’S BUILD TO YOUR SPECIFICATIONS
Develop Your Next Helmet Shell with JOHHAR
Send us your existing shell CAD, drawings or sample information to discuss feasibility and tooling.