We are manufacturers of motorcycle helmets in Italy

Where we produce our helmets

All CAST motorcycle helmets and the professional and military helmets are produced exclusively in Italy, by our specialized personnel, in the plants of Busto Arsizio (Varese).


The shells of the helmets commonly called "in Fiber" are produced by impregnating a composite fiber acting as a supporting structure with "binding" hardener resin and determines the strength and characteristics of the helmet.

The type of fiber used makes the difference to obtain the most performing and lightest helmets, as the cheaper and less performing fibers are the heaviest. An economic and low-performance fiber helmet can be verified from the "high" weight.

Molding is done in our factory, obtaining a quality shell is subject to the operator's experience.

Helmet visor production

It is a fundamental and decisive element for assessing the overall quality of a helmet. Even the visor is designed and produced entirely in our factories.

The phases of its processing include:

  • Molding: carried out with robotic machines. The cycle includes a check carried out with polarized lenses to verify their perfect correspondence. Continue reading (PDF)
  • Anti-abrasion and anti-fog treatment: the visor undergoes an anti-abrasion treatment on the external surface and permanent anti-fog on the internal surface. The treatment makes it possible not to use internal visors, which reduce visibility, invalidating safety and sometimes making the helmet unapproved.
  • Test: the helmet is then subjected to a complete test cycle to guarantee perfect compliance with current regulations.

Fabrics we use for our helmets

We care about your health as well as your safety
Chosen to guarantee extreme health and comfort, the fabrics we use for the interior of our helmets are produced in Italy and are free from irritating, toxic and carcinogenic substances. The STANDARD100 OEKO-TEX certification guarantees them "free from amines and substances harmful to the skin", often the cause of allergies, eczema and serious damage to health.


Full Carbon Tecnology
Thanks to the development of the carbon fiber helmets production technology, we can produce helmets that are clearly superior to the traditional ones. Carbon fibers impregnated with epoxy resins are currently the best high-tech material that the industry is able to produce in appreciable quantities.

"Carbon technology allows to obtain lighter and more resistant helmets, with a high kinetic energy distribution in the event of impacts.
For this reason Cast continues to invest in the development of this fiber to obtain the best possible safety helmet."

The pluses of a carbon helmet

High rigidity
thanks to the greater rigidity of carbon fibers, the impact is evenly distributed on the helmet shell.

Active safety
decreasing the weight decreases the pilot's fatigue and therefore increases attention and reflexes.

Passive safety
lower helmet weight also means less kinetic energy produced during impacts.

Carbon Look and Full Carbon

The difference between Appearing and Being
On the market there are helmets that simulate the Carbon structure through a simple painting. How to distinguish a real Carbon helmet from a helmet that is not?

it is the most complicated and most reliable system. It allows to analyze the fibers of the material of which the helmet is made. Carbon is transparent to X-rays.

Helmet weight
is the most intuitive and simple method. To distinguish a Carbon Fiber helmet from a traditional one, check it from its weight.

Carbon Square

The innovative CAST technology
CAST has taken another step forward in the use of carbon technology for helmets. The new "multi-orientated super fiber", used in the aeronautical, military and Formula 1 fields. It allows to produce lightweight and even more resistant shells, thanks to a high impact distribution along the fiber net.