The History of Protective Motorcycle Apparel : 1920’s to 2025 – From makeshift gear to Intelligent Safety Systems
Motorcycling has never merely been a method of transportation—it’s a way of life, a revolution, and a display of human resourcefulness. For the last century, protective equipment worn by riders has changed quite a bit. What was initially a haphazard assembly of military surplus and work gear is now a refined blend of high-tech materials and intelligent technology. In this deep dive, we’ll journey from the earliest full gear sets to modern high-tech innovations, explore how retail channels evolved, examine global penetration figures, and look ahead to future trends that will continue to reshape motorcycle safety.
References and Links to sources. We are not showing any pictures from the sources as they don’t belong to us and all these are editorial pieces so we don’t want to use them and say image source. The links are below and they make for enthralling read. Do read
The Evolution of Motorcycle Style –GQ
History of Motorcycle Apparel –Pando-Moto
History of Motorcycle Armor –Great Lake Supply Co.
FL Bikers – A History of Motorcycle Gear –FL Bikers
Voss Helmets USA – Motorcycle Gear Evolution –Voss Helmets
The Evolution of Motorcycle Clothing –Florida Motorcycle Rider
Motorcycle Personal Protective Equipment –WikiPedia
Aerostich –WikiPedia
Wikipedia – Dainese –WikiPedia
Now for our blog…
I. The Dawn of Motorcycle Gear: The First Full Set
During the early years of motorcycling—approximately the 1910s to the 1930s—there was no such thing as a “motorcycle gear” industry. Motorcyclists made do with whatever they could salvage, repurpose, or have custom-made by local artisans. Here’s what that early gear consisted of:
1.Helmet: Repurposed from Aviation Helmets
Type: Aviator-style soft leather or pith helmets
Origin: Often borrowed from World War I aviation or military use
Features: Very little protection, made more for windproofing than shock absorption
Reality: During a crash, these helmets had little more than a thin barrier between the rider and the road.
2. Jacket: Military Surplus & Heavyweight Leather
Type: Thick cowhide leather or military-issue wool coats
Origin: Bought from army surplus stores or made by local leatherworkers
Features: Tough, long-lasting, with reinforced seams and additional layers on elbows and shoulders
The Reality: Adequate for deflection of wind and small abrasions, yet without any present impact protection or ventilation, which left them hot and rigid.
3.Gloves: Workman’s Essentials
Type: Heavy leather work gloves
Origin: General-purpose equipment from farm or industrial hardware stores
Features: Offered grip and moderate abrasion protection
The Reality: Upon the crash, little in the way of impact protection, leaving rider’s hands subject to extreme road rash.
4. Pants: Jeans, Wool Trousers, or Riding Breeches
Type: Heavy-duty denim, wool, or specially made riding breeches
Origin: Salvaged work clothes and horse riding equipment
Features: Heavy-duty material designed to protect against abrasions
The Reality: Without any reinforcements such as Kevlar, these pants would easily deteriorate in a slide.
5. Boots: High-Top, Heavy-Duty Footwear
Type: Military-issue or engineer boots
Origin: Frequently obtained from surplus or as work boots for railroad engineers
Features: Tall leather construction with steel shanks for ankle support
The Reality: While they provided some protection, they were rigid and weighed heavily, and could easily be breached in a high-speed collision.
This patchwork outfit came into being out of necessity—each piece of equipment was a survivor, cobbled together by riders who had no other option. It was an era of perpetual risk and improvisation, where each scratch and scuff was a testament to defiance against the perils of the open road.
II. Breakthrough Inventions That Reshaped Rider Protection
As motorcycling became more popular, so did the demand for improved, specially designed gear. Throughout the decades, a few influential innovators and forward-thinking brands transformed motorcycle safety with revolutionary inventions. Below are the milestones that transformed the game:
1928: The First Real Motorcycle Jacket – Schott NYC and The Perfecto
Prior to Schott NYC’s game-changing design, motorcyclists were relegated to generic military jackets or wool sweaters that did little to save them in a crash. Along came Irving Schott, a leather maker who had an innovative thought, “What if we created a leather jacket designed specifically for motorcycle riders—hard enough to withstand a crash, but fashionable enough to wear anywhere?”
The outcome was The Perfecto, which debuted in 1928
Among its key characteristics were:
Thick cowhide leather for maximum abrasion resistance
Diagonal zipper for added wind proofing
Close-fitting cuffs and belt to provide a secure fit
The Perfecto became legendary when Marlon Brando wore it in The Wild One (1953), making the motorcycle jacket a symbol of rebellion and tough style.
1953: The First Mass-Produced Motorcycle Helmet – Bell & Roy Richter
Prior to the age of standardized helmets, riders made do with padded leather caps—little more than paper bags in a crash. Along came Roy Richter, a racer and equipment aficionado who saw the need for improved head protection. By marrying a fiberglass shell with EPS foam lining, Richter developed the Bell 500—the first motorcycle helmet to be designed to absorb impact.
Bell Helmets continued to change head protection with the launch of the full-face helmet in 1968 with the Bell Star.
All major helmets today remain true to the pioneering design standards established by Bell.
1965: The Kevlar Revolution – DuPont & Early Adopters
By the 1960s, rider protection was dominated by leather. Leather had an Achilles’ heel in the form of tear-out when one slid at speed. In 1965, chemist Stephanie Kwolek at DuPont was testing new lightweight fibers when she stumbled on Kevlar—a fiber that was five times stronger than steel.
Within a decade, motorcycle brands began integrating Kevlar into riding pants and jackets, significantly enhancing their abrasion resistance. Pioneers such as Dainese and smaller innovators like Draggin’ Jeans (later in the 1990s) led the charge, ushering in the era of textile-based protective gear that broke leather’s 50-year reign.
1978: The Birth of the Modern Riding Suit – Aerostich’s Roadcrafter
For many years, riders had to decide between rough leather gear or comfortable street clothes. Andy Goldfine of Aerostich broke the mold in 1978 with the introduction of the Roadcrafter suit—the first armored, weather-resistant, one-piece riding suit ever made from Cordura nylon.
It incorporated:
Integrated armor for key impact zones
A design that was simple to put over street clothes
Water- and wind-proof construction
The Roadcrafter became legendary among long-distance riders and galvanized a generation of brands such as Klim, Rukka, and Rev’It! to create sophisticated touring equipment.
1979: Gore-Tex Rolls In – Waterproofing Without the Sweat
Until Gore-Tex came onto the scene, riding in the rain was a terrible experience. Old rain gear was usually constructed from plastic that retained sweat and provided lackluster breathability. Bob Gore originally came up with Gore-Tex in 1969, using a microporous membrane that lets sweat evaporate without letting rain in. By 1979, BMW and Rukka started incorporating Gore-Tex into motorcycle jackets, which were both waterproof and breathable—a game-changer for adventure and tour riders.
Gore-Tex is still the gold standard for waterproof motorcycle apparel today.
2001: D3O – Armor That Moves With You
Before the early 2000s, impact armor existed mainly in the form of hard plastic materials that were protective but heavy and restrictive. British scientist Richard Palmer created D3O in the early 2000s, a “non-Newtonian” material that remains soft at regular conditions but hardens immediately upon impact to absorb and dissipate shock.
Brands such as Icon, Klim, and Dainese soon picked up on D3O, adding it to jackets, gloves, and even CE-rated riding boots. This innovation delivered flexible, light, yet very effective protection, and D3O became an industry darling. Now, D3O can be found everywhere in contemporary protective gear.
2006: The Motorcycle Airbag – Dainese vs. Alpinestars
Airbags were the preserve of the motor car world—until Dainese unveiled its D-air airbag system in 2006. The technology placed an airbag within a motorcycle jacket that inflates in milliseconds on impact, protecting the rider and minimizing the chances of serious harm. Feeling left behind, Alpinestars came out with its own Tech-Air system in 2014, positioning itself directly against Dainese.
Airbag systems now stand as the greatest innovation in motorcycle safety since helmets, and both track and street riders are enjoying this lifesaving technology.
2009: SuperFabric – The Toughest Textile Ever
By the late 2000s, riders were calling for gear that would pair the strength of leather with the lightness and flexibility of new fabrics. SuperFabric came onto the scene in about 2009 as a high-tech fabric infused with microscopic ceramic armor plates, providing astounding abrasion resistance, flexibility, and durability.
Brands such as Klim, Rukka, and Rev’It! incorporated SuperFabric into their premium adventure apparel, offering protection that wore hardly a hint of damage even after hard encounters with asphalt.
III. The Evolution of Motorcycle Gear Retail: From Surplus Stores to Digital Empires
The history of motorcycle gear isn’t only the story of materials and design breakthroughs—it’s also the history of how the retail environment developed to accommodate increasing rider demand.
1900’s to 1940 – DIY and Surplus Shopping
1900s-1940s: In the early days, there were no dedicated motorcycle gear shops. Motorcyclists sourced helmets from aircraft shops, jackets and boots from surplus military stores, and worn-out work garments for gloves and pants. Custom-tailored items by local tailors were the standard for those who had the means.
The DIY Age: Riders tended to do what they could to add extra layers, repair seams, or enhance fit. Equipment was a patchwork of whatever materials were available, solely based on necessity.
1950s-1970s: From Dealerships to Mail-Order Catalogs
Motorcycle Dealerships: As motorcycles went mainstream, dealerships started carrying riding gear. Early brands such as Belstaff, Lewis Leathers, and Schott NYC became household names.
Mail-Order Revolution: Sears & Roebuck and other companies sold equipment through mail-order catalogs, increasing the availability of protective gear to an expanding rider base.
Iconic Gear on Display: Breakthroughs such as Bell’s full-face helmets (1968) and the emergence of purpose-built jackets marked a sea change in gear design and marketing.
1980s-1990s: The Rise of Specialty Retailers
Specialty Shops: This decade witnessed the onset of specialty motorcycle apparel shops apart from bike dealership shops. Store owners started dealing in a huge variety of gear, appealing both to safety-orientated and fashion-conscious customers.
European Innovation: The influx of armored, high-performance products from companies such as Dainese, Alpinestars, and continental manufacturers raised the bar for security clothing. Customers could now test gear that underwent stringent impact-absorbing testing and comfort.
2000s-Present: The Digital Revolution and the Age of E-Commerce
Online Leaders: Online giants like RevZilla, Cycle Gear, FortNine, Motocard, and BikeBandit rule the roost today. RevZilla, which began in 2007 from a modest Philadelphia warehouse, has expanded into a multi-million-dollar business and is widely known as one of the big five in motorcycle apparel retail.
Online vs. Offline Sales: Globally, estimates indicate that 60–70% of motorcycle gear is now purchased online, especially in North America and Europe, driven by convenience and a vast selection of products. In contrast, regions like China, India, and Thailand still rely heavily on brick-and-mortar stores—though the online market is rapidly growing there.
Retail Dynamics: Although premium and performance equipment tends to be purchased online because of its niche character, most motorcyclists in emerging markets still prefer offline retail where they can try on equipment and get expert opinions directly.
IV. Global Penetration and Market Dynamics
Knowing how motorcycle equipment is embraced throughout the world provides insights into global safety trends and market potential:
United States: Penetration: About 40–50% of motorcyclists wear a full set of safety equipment. Helmet wearing is almost universal, but other safety items such as jackets, gloves, and boots are frequently left behind by casual riders.
European Union: Penetration: With enforced safety regulations and widespread safety culture, 60–70% of motorcyclists in the EU wear a full set of gear.
China: Penetration: Due to affordability concerns and lower awareness of safety, as one of the largest motorcycle markets, only around 10–20% of motorcyclists wear full protective gear.
Thailand: Penetration: For Thailand, where motorcycles are widely used as a means of general transportation, penetration for gear usage is at around 15–25%, with helmet use being predominant.
India: Penetration: Full gear usage remains fairly low at 10–15% in non-metropolitan areas, although helmet requirements have made overall usage more widespread.
NOTE – These figures seem on the higher side but there is no ONE source available to confirm.
V. Future Trends: The Next Frontier of Motorcycle Safety
Looking ahead, motorcycle apparel will become even more integrated and smart. Emerging trends indicate a future where protective gear does much more than just protect riders—it actually adds to the riding experience and saves lives.
Smart Helmets and Connected Gear
AI-Assisted Alerts: Future helmets may incorporate augmented reality (AR) displays and AI systems that provide real-time hazard alerts, navigation, and performance data.
Integrated Communication: Helmets and jackets could soon work in tandem with your motorcycle’s systems, creating an ecosystem where gear continuously communicates vital information.
Adaptive Armor and Self-Adjusting Materials – Dynamic Protection: Envision products that are able to vary their stiffness with respect to speed or impact—adapting in real time to offer maximum protection when required.
Sensor-Integrated Gear: New gear may be able to monitor vital signs, monitor fatigue, or even automatically alert emergency responders in the case of a crash.
Sustainable and Customized Gear Eco-Friendly Materials: With greater environmental consciousness, future gear can be created using sustainable, recycled materials that maintain the same level of safety.
Customization: Advances in manufacturing technology could enable highly personalized gear, tailor-made to a rider’s specific body shape, riding style, and safety needs.
goodgearhub wrapup A Legacy of Innovation and the Road Ahead. The history of protective motorcycle attire is an amazing tale of need and innovation. From the hodgepodge outfits of the early 20th century—made up of surplus helmets, thick leather coats, and modified work clothes—to the advanced, high-tech systems of the present day, each innovation has been spurred by the dual necessities of survival and performance.
Visionaries such as Irving Schott, Roy Richter, Stephanie Kwolek, and today’s innovators such as Dainese’s and Aerostich’s groups have not only saved lives but also changed the very nature of riding. The evolution of retail—from mail-order catalogs and military surplus stores to specialty dealerships and online forums—has paralleled the development of the industry, bringing good-quality gear within reach of motorcyclists globally.
Penetration rates worldwide reflecting both success and potential—and the trends of tomorrow promising even more integrated, smarter, and sustainable solutions—the motorcycle gear journey has only just begun. As technology keeps evolving, the gear we wear will not only keep us safe but enhance the riding experience in ways our forebears could hardly envision.
The next time you zip up your jacket or buckle on your helmet, consider taking a moment to admire the history of innovation and the boldness of those who came before. Ride safe, ride smart, and become part of the continually changing ride on two wheels.
Always wear riding gear. It elevates the joy of motorcycling and frankly its not optional.
This blog took us weeks to compile. We wanted to understand the history and share it with you. goodgearhub aspires to be the what, how and where of riding gear with your help.
Ride on. Ride more.
