How can I set-up a Motorcycle Helmet Manufacturing Company? What kind of equipment would someone need?

Question

I have an Engineering degree, I have the financial resources and the land to set-up a company like that. No need to mention that I am a passionate Motorcyclist.I just don't know how to plan it or what kind of equiment and business connections I need.

Answer 1

Dear Engineer, if you really like to put up a helmet company, you buy one design that you want to produce, tear it down piece by piece ad see how what/how it is made. I do not have an eng'g. degree but my observation is that there are so many companies already in China and Taiwan producing them, either the full face model or the "German" model, you know, like what the German soldiers wear then. You only need a stamping machine, where you have a a metal pattern, and you drop that metal pattern onto a piece of metal ( like Bell helmets ). When you hold that sheet of metal against the lathe, it will transform into the helmet's basic shape, and then trim it in later steps.  Or, simply form casts, where you pour polyethylene or other plastic materials on your model form/cast, then have the foam and textiles inside as trimmings, and the paint outside. That's relatively easy. But this latter one does not afford ample protection in crashes, because of the weaker material. That's basically what you can get from China and Taiwan. The Shoei and Bell are the better, professional brands, but more expensive.

Answer 2

What an unusual idea!

First, you need to research the safety standards you'd need to meet, and cost out the initial tests to get your products E marked & ACU licensed. Buy a few used or damaged lids & teke them apart to see how they're made, research what people are buying, etc.

Go round some bike shows with long legged women & a survey - find out what people want, what they'll pay, etc.

You then ideally need a USP - a unique selling point - something that'll make folk give their money to you rather than one of the other many companies that are doing a similar product: Crack this, and you've got it made!

Answer 3

Great Idea, but a tough market. There are several Companies that you can actually tour the factories to see how its done. Not to long back on speed channel they did a show on Shoei Helmets. I believe that there are only a small amount of actual companies making all the helmets for other companies. Wish I had more info, try writing to the industries magazines they may reply with the info that you need.

Answer 4

You'll have to find someone in the injection molding business and have them make up sets of dies.  Dies are the metal fixtures that molten plastics get injected into and then becomes the item.

You'll need a die for the polycarbonate outer shell, which will be injection molded.  There are plenty of folks to do that for you, and they'll have names and numbers of die makers that they recommend.  You'll need a die for the kevlar liner, which you'll also need a big bad oven to put your parts in to bake if you're doing that yourself.  You'll need a die for the polystyrene or polypropylene foam as well, you can have the same die maker do all of them.

After you've started selling some, you can buy the equipment to do all the injection molding yourself, or maybe have your own die making shop which would involve CNC lathes and mills, 3 axis machines, and so on.

You would need basic painting equipment and a spray booth.  Custom graphics guys usually bring their own tools to work.

You'll need to contract for the sewing of the fabric liner.  If you don't care what country they get sewn in, you can have most of it done very cheaply.

Don't let folks say you can't do it.  Build a better mousetrap and the world will beat a path to your doorway.

Answer 5

I'm not sure but I like your spirit! Go for it!

Answer 6

Might be worth speaking to some of the established manufacturers to see if you can make an agreement to manufacture their lids under licence, that way you'll be able to use their expertise to actually set up the factory. You could maybe use this as as a springboard to eventually developing your own brand but that would depend on how tightly bound you were by any agreement.

If you start from scratch you're going to have to come up with a design, then go through the (presumably very complicated and expensive) approval tests before you can then go into the market place. Bearing in mind you're dealing with protecting peoples lives it may take some time before your brand is recognised as being trustworthy.

Good luck.

Answer 7

I think that if you go with this ideal in a year or so your next statment will be:  How do I ???......I'm now BROKE but want to try something new...

In other words don't waste your time or money,  you just can't compete in that market...

Answer 8

I work for one, my advice is don't do it.  Although I salute your ambition and passion for biking, the global market is heavily saturated, and competition is extremely fierce.  In the current world economic climate, it would be a very severe risk, especially in light of your admitted lack of knowledge.  The Chinese manufacturers have it all sewn up at the moment.  The only things that would work in your favour is if you can do it better, or massively cheaper than anyone else.  The existing big names have decades of research behind them, and the Chinese have people working for a bowl of rice a day.  Can you beat those?