Reclaim, Regrind, Reuse: Turning Auto Industry Scrap EPS into New Helmets
Plastics are everywhere — and they’re a major driver of climate change. Global CO₂e emissions exceed 54.6 billion tons annually, and plastics account for roughly 3.3% of that total, with nearly 90% coming from their production stage, rather than disposal.
At Strategic Sports, we’re tackling this problem head-on by transforming reclaimed EPS from the Japanese auto industry into high‑performance helmet liners — a breakthrough that dramatically reduces our reliance on virgin petrochemical plastics.
This effort is part of our broader commitment to operate on 100% renewable energy and achieve carbon neutrality by 2030. Alongside major sustainability upgrades to our factories in Vietnam, Portugal and China, we’re rethinking how and where we source materials to reduce environmental impact without compromising safety or performance.
Our Three R’s: Reduce, Recycle, Replace
Reduce virgin plastic by increasing regrind material use
Recycle wherever possible to close the materials loop
Replace petrochemical plastics with biobased alternatives when viable
Why EPS Matters
The helmet liner — typically made of expanded polystyrene (EPS) — is the largest single component in most helmets and the key to their energy‑absorbing, life-saving performance. EPS compresses under impact to manage crash forces and help prevent injury. While alternative materials exist, few meet the same safety standards without significant design trade‑offs. Simply put, EPS remains unmatched for impact protection.
That’s why our challenge wasn’t to replace EPS — it was to make it sustainable.
Regrind EPS from the Auto Industry
We collect surplus high‑grade EPS used in automotive safety components from leading Japanese automakers. This material is then compressed, reprocessed, and transformed into 100% recycled EPS liners for cycling, snow, motorsports, equestrian, and industrial helmets — delivering the same performance as virgin material with a fraction of the environmental footprint.
Several major brands are already using Strategic Sports regrind EPS in production models.
“Our ultimate goal is to create a circular economy where old helmets become new helmets. Regrind EPS is a critical step toward a vision of truly sustainable and green helmet production for our partners.”
-Norman Cheng, Strategic Sports Managing Director
Beyond the Liner: BioDome Materials Innovation
The EPS liner may dominate a helmet’s volume, but it’s far from the only part we’ve reimagined. Our BioDome platform extends reclaimed, renewable, and recycled materials to buckles, straps, shells, and other sub‑components, using such materials as bamboo and plastic water bottles reclaimed from the ocean. This materials innovation powers our award‑winning lineup of recyclable and recycled‑content helmets — including the Red Dot Award–recognized S‑460 RMR urban model, built entirely from reclaimed, recycled, or recyclable materials.
A Win for the Planet, Our Partners, and their Customers
We pursue sustainability because it’s the right thing to do for the planet — and because it matters to riders and brands alike. Sports consumers increasingly expect eco‑friendly products and look to brands that integrate real, measurable environmental action. Our approach ensures that sustainability isn’t an add‑on; it’s embedded in our product platforms from the start.
Part of a Bigger Plan
Regrind EPS is just one element of our wider sustainability roadmap. Strategic has aligned its goals with the Science Based Targets Initiative (SBTi) — the leading global framework for measurable corporate carbon reduction. This includes carbon benchmarking, transitioning our facilities to green energy, and embedding circular design principles into all new products. We’ve also achieved ISO 14001 Certification for Environmental Management.
Our ambition is clear: lead the industry in sustainable helmet manufacturing by rethinking every stage of the process — from material sourcing to logistics to manufacturing practices. What begins as automotive scrap ends as a helmet built to protect both you and the planet.