First: What Does a Helmet Shell Actually Do?
The outer shell is only one part of a complete helmet protection system.
During an impact, the shell helps distribute forces over a larger area, resist penetration and
abrasion, and protect the energy-absorbing structure underneath. Beneath it, the EPS liner
is designed to compress and manage impact energy.
The shell works together with the helmet’s EPS liner, retention system, interior fit, geometry and overall design. That’s why it’s important not to judge a helmet’s protective performance by shell material alone.
ABS, fiberglass and carbon fiber can all be used to engineer protective, standards-compliant motorcycle helmets.
What changes is how manufacturers get there.
ABS THERMOPLASTIC
Proven. Durable. Accessible.
ABS stands for Acrylonitrile Butadiene Styrene, a durable thermoplastic widely used in motorcycle helmet construction.
Unlike composite materials, ABS begins as a plastic material that can be heated and formed. During helmet manufacturing, the material is typically melted and injection molded into the shape of the outer shell, then cooled and finished.
This manufacturing process is highly repeatable and efficient, making it possible to produce strong, complex helmet shells at scale.
Why use ABS?
ABS offers a combination of durability, impact resistance, manufacturing consistency and affordability. It's one of the reasons thermoplastic helmets can deliver reliable everyday performance without carrying the price tag of more labor-intensive composite construction.
Key Benefits
- Strong and Durable
- Impact and abrasion resistance
- Consistent manufacturing
- Cost-efficient
The primary trade-off is weight. Depending on the helmet's design and performance requirements, an ABS shell may require more material than a composite alternative, which can contribute to a heavier finished helmet.
Who is ABS for?
ABS is an excellent choice for riders looking for dependable protection and maximum value.
Within the Voss lineup, ABS allows us to offer accessible helmets across several riding categories—from everyday full-face and modular helmets to dual-sport and motocross designs.
BEST FOR:
Everyday riding, durability and value.
Fibreglass Composite
The performance sweet spot.
Fiberglass takes helmet construction in a different direction.
Instead of molding the shell from thermoplastic, fiberglass shells are made using fine glass fibers combined with a resin matrix. Together, these materials create a fiber-reinforced composite structure.
Multiple layers and orientations of reinforcement can be used to engineer the shell's strength and behavior while maintaining a favorable strength-to-weight balance.
Composite construction is generally more involved than injection molding, which contributes to its higher manufacturing cost. But it also gives helmet engineers different opportunities to optimize the shell.
Why use fibreglass?
Fibreglass occupies an important middle ground.
It can provide composite construction and favorable strength-to-weight characteristics without the premium material cost associated with carbon fiber.
KEY BENEFITS
- Favorable strength-to-weight ratio
- Composite performance
- Lighter weight potential than ABS
- More accessible than carbon
For riders, that can mean a lighter, more performance-oriented helmet while keeping the price considerably more accessible than a comparable carbon fiber design.
This is exactly why we've introduced fiberglass into the Voss lineup.
Meet Voss FibreTek
The 991 FibreTek brings composite shell construction to the 991 platform using fiberglass rather than carbon fiber.
It gives riders another way into Voss's premium full-face category while offering DOT and ECE 22.06 certification and a more accessible price point than our flagship carbon fiber construction.
Fiberglass isn't simply a cheaper version of carbon. It occupies its own sweet spot between the manufacturing efficiency of ABS and the lightweight performance potential of carbon fiber.
BEST FOR:
Riders seeking the balance between weight, performance and price.
SHOP 991 FIBRETEK →
Carbon Fiber
Premium material. Lightweight performance.
Carbon fiber is another fiber-reinforced composite, but instead of glass fibers, it uses extremely fine strands of carbon.
These fibers can be arranged into woven or other reinforcement structures and combined with a resin system to create an exceptionally strong material relative to its weight.
Its exceptional strength-to-weight characteristics are why carbon fiber appears far beyond motorcycle helmets—in applications where reducing weight while maintaining structural performance is highly valuable.
Why does carbon fiber cost more?
You're not simply paying for the exposed carbon weave.
Carbon fiber itself is a significantly more expensive raw material, and producing a quality carbon composite shell involves specialized materials, tooling, manufacturing processes and quality control.
The payoff is excellent strength-to-weight potential, allowing engineers to pursue highly capable shell structures while minimizing unnecessary mass.
Key Benefits
- Excellent strength-to weight potential
- Premium construction
- Specialized manufacturing
- Lightweight performance
On a motorcycle helmet, reduced weight can be particularly valuable during longer rides, performance riding and extended periods at highway speeds.
The Voss 991 Carbon
The 991 Carbon represents the flagship end of the Voss full-face lineup.
Its carbon fiber shell is designed for riders who prioritize premium materials, lightweight construction and performance-oriented design and are willing to invest more to get them.
BEST FOR:
Riders prioritizing premium construction and minimum weight.
SHOP 991 CARBON →
ABS vs. Fibreglass vs. Carbon Fiber
| ABS | Fibreglass | Carbon Fiber | |
|---|---|---|---|
| Material | Thermoplastic | Glass-fiber composite | Carbon-fiber composite |
| Typical construction | Injection molded | Fiber + resin composite | Fiber + resin composite |
| Weight potential | Generally heavier | Lighter-weight potential | Greatest lightweight potential |
| Manufacturing complexity | Efficient & scalable | More involved | Highly specialized |
| Relative material cost | $ | $$ | $$$ |
| Voss positioning | Accessible performance | Performance/value balance | Flagship performance |
| Best for | Everyday value | Balanced upgrade | Premium lightweight construction |
So, Which Helmet Material Should You Choose?
There isn't one correct answer.
CHOOSE ABS IF
You want dependable performance and maximum value.
CHOOSE FIBREGLASS IF
You want compostie performance and reduced weight without the carbon price.
CHOOSE CARBON FIBER IF
You prioritize premium materials, lightweight construction and are willing to invest more.
Choose ABS if
you want dependable everyday performance and value. Modern thermoplastic construction makes it possible to build capable helmets at accessible price points.
Choose fibreglass if
you want to step into composite construction, reduce weight and gain a more premium helmet platform without paying the full premium associated with carbon fiber.
Choose carbon fiber if
weight and premium construction are priorities and you're willing to invest more for carbon's exceptional strength-to-weight characteristics.
The easiest way to think about the Voss material hierarchy is:
ABS
VALUE + DURABILITY
FIBREGLASS
PERFORMANCE + VALUE
CARBON FIBER
PREMIUM + LIGHTWEIGHT PERFORMANCE
Does Carbon Fiber Automatically Mean Safer?
No—and this distinction matters.
Shell material alone does not determine whether one motorcycle helmet is safer than another.
A helmet is a complete system. Its performance depends on the interaction between the outer shell, EPS impact liner, retention system, geometry, fit and numerous other design decisions.
That's also why ABS, fibreglass and carbon fiber helmets can all be engineered to satisfy applicable motorcycle helmet safety standards.
Certification evaluates the performance of the complete helmet—not simply what the outer shell is made from.
A more expensive shell material can offer meaningful advantages, particularly in weight and construction, but price should never be treated as a simple safety rating.
The Right Material Is the One That Fits Your Ride
Helmet materials have evolved considerably, but the goal remains the same: build a complete helmet system capable of protecting the rider while balancing comfort, weight, performance and cost.
ABS makes capable helmets accessible. Fibreglass brings composite performance into the middle of the range. Carbon fiber pushes toward the premium end of lightweight construction.
Different materials. Different advantages. Same goal.
Find the helmet built for your ride.
ABS
Proven protection across the lineup.
FIBREGLASS
Composite perfromance, more accessible.
CARBON FIBER
Our flagship in lightweight performance