Client Description
SHOEI has been dedicated to the development of superior helmet technology since 1958. SHOEI helmets are more than just a brand. SHOEI features an unmatched, unyielding commitment to safety and comfort that is race born and rider tested. For more than 40 years, SHOEI helmets have revolutionized the motorcycle helmet industry SHOEI's reputation as a top quality brand spread first over the U.S., then later all over the motor markets of Europe and the rest of the world.
The Challenge
Optically Correct Visors
SHOEI selected MXL to provide mold design / development and molding / coating services for various complex-curve, optically correct helmet visors. SHOEI is the world's premier safety helmet manufacturer, and as such they have extremely stringent quality requirements. Zero distortion is a must to ensure zero distraction in demanding track and street riding.
Complex, Molded-in, Visor Ratchet and Attachment
SHOEI's custom design ratchet mechanism is a complex, molded feature that allows for tool-free visor replacement without sacrificing the physical integrity of the helmet / visor system. The challenge is compounded by the fact that this is an extremely high volume part and the mold surfaces and moving components must hold up to hundred's of thousand's of shots.
Innovative and Functional Lens Designs
At the forefront of the safety helmet industry, SHOEI requires new, functional innovations in visor design. These innovations must be more than cosmetic; they must pass all of the same, stringent quality requirements of their regular visors. Colors, coatings, and performance enhancements are critical to the marketability of these products.
The MXL Solution
MXL was chosen to design and manufacture a variety of helmet visors for SHOEI. MXL leveraged its vast manufacturing background to make key mold design decisions that put SHOEI well ahead of the industry, in particular the custom design ratchet mechanism that has been often copied.
MXL developed molding, coating and mirrorizing (chrome, blue and gold) processes to satisfy SHOEI'S needs. Additionally, MXL developed specialized manufacturing and quality procedures to support SHOEI's requirements.
Currently MXL produces more than five models, in many substrates, and several coating combinations to achieve more than 300,000 visors per year. MXL is SHOEI USA's sole supplier.
Value Added Services
MXL provides additional services making us an end-to-end solution for our customers.
- Worldwide drop shipment of manufactured parts
- Packaging for retail sales
- Specialized manufacturing and assembly for dedicated racing visors
- Ongoing R&D focused on improved optical performance in specific environmental conditions
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