22E006 – Helmets May Not Protect From Impact – Nexxpro X.R2 Motorcycle Helmets

SEOCONTENT-START

~ r, –·~~
HELMETS
FOR LIFE
Via Electronic Mail
December 6, 2022
Pedro Duarte
Nexxpro – Fabrica de Capacetes, S.A.
Zona Industrial Amoreira da Gandara, Lote No. I I
3780-024 Amoreira da Gandara, Portugal
Subject: Missing CY2022 Recall Information (Delay in Notifying Owners – NHTSA
ID#22E006)
Dear All,
We hereby explain why the owner notification letters were not, so far, issued for this
recall.
1. Our dealer of nowadays (“VL”) is not the same of 2019’s, and since we have
an Nexx North America (NNA) warehouse, we had to check to which dealer
the affected helmets were sent.
According to our analysis, it is now ce1iain that were not sent to VL, and most
probably to Rev’it. Due to this, we are facing the second issue.
11. Between 2019 and 2020, our representative at NNA (Nexx North America)
and Rev’it resign and the whole organization was modified.
According to information it seems that at the time it was a harsh process,
almost leading to NNA’s end,
Due to this we are now facing major issues to obtain any information from
NNA & Rev’it (mainly in what concerns helmets sent to USA before 2020).
m. It is planned now to, with VL’s assistance, make an approach to every dealer
(the ones of 2019) to find out where the affected helmets are and to whom
were sold.
To prevent this from happening in the future, and as described previously, since 2020 we
have a different company (VL) working with us, with a different approach, more
professional, and with a capable traceability system.
ne:xxpro
fabrica de capacetes. S.A.
Soded.’lde .Anofjm11 NIPCJVAT:505 376 113 Cnpital Soclal (615.385,00 R~Uto CJl.C CH Anlldia sob o n• 505 376 113.
. , d capacetes, SA.
neXXl)rO I fabric& . ~- “‘””ata \Lole N’ ,,
slJialdeAimrefawuolll’ a\
Zona lndU reifa da GAndara I Nladia-l>otlu9 1 3780-024MV) NIPC: 505376\1•3-~ ~,-, .. ~
A n.1o liqu~1o d&Sta doc\lmento dE 3780-024Amollira da Gindara I Analfia.Portugal
, NIPC: 505376113
Issued.’ [July} {2023}

**************************************************************************************************************

1
Pedro Duarte
De: Pedro Duarte
Enviado: 15 de fevereiro de 2022 14:41
Para: Eric Van Leeuwen
Cc: Hélder Loureiro; António Patrício
Assunto: FW: Acknowledgement letter for Recall Campaign Number: 22E006
Anexos: RCAK-22E006-9909.pdf; Nexx X.R2_Product-Recall-Notice.docx
Importância: Alta
Dear Eric,
First of all, I hope you are doing well.
As you surely know, we are proceeding with a recall campaign for model X.R2. Details in attachment.
To start up, I kindly ask you to please:
1. check the attached product recall notice and to fill in your contact details, and then return it to me;
2. Inform us if, with the serial number of the affected helmets, it will be feasible/possible to find the end consumer on an estimated 30 days period.
(I know that this one is a tricky question, but I need to be aware of the recall campaign process to evaluate if we’ll need additional support.)
Thanks.
Cumprimentos / Best regards,
Pedro Duarte
Diretor da Qualidade / Quality Manager
[email protected]
2
Nexxpro, S.A.
Zona Industrial Amoreira da Gândara, Lote Nº11
3780-024 Amoreira da Gândara
Portugal
Phone. +351 231 590 010 / +351 925 949 259
Fax. +351 231 596 861
Email. [email protected]
www.nexx-helmets.com
De: Lee, Choon (NHTSA) <[email protected]>
Enviada: 10 de fevereiro de 2022 14:46
Para: Pedro Duarte <[email protected]> Assunto: Acknowledgement letter for Recall Campaign Number: 22E006
Importância: Alta
Hello Mr. Duarte,
Please review the attached acknowledgement letter for recall 22E-006 and ensure it matches your information. It is scheduled to be posted to NHTSA.gov tomorrow
morning.
Thank you and stay safe,
Choon Lee
Safety Recall Specialist
U.S. Department of Transportation
National Highway Traffic Safety Administration
Office of Defects Investigation
1200 New Jersey Avenue SE., Washington, DC 20590
W46-430
Tel: 202-366-0388

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-006
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Submission Date : MAR 16, 2022
NHTSA Recall No. : 22E-006
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Address : Zona Industrial Amoreira da Gandara
Lote 11 – Amoreira da Gandara –
Anadia Anadia 00 3780-024
Company phone : 231590010
Population :
Number of potentially involved : 12
Estimated percentage with defect : 67 %
Equipment Information :
Brand / Trade 1 : NEXX
Model : X.R2
Part No. : 01XR22312455100M
Size : M
Function : Safety
Descriptive Information : – On the 1st of march’19, it had been reported/detected a setup machine failure,
leading to 18 non-conforming products. Those parts were submitted to a rework
process.
– Due to lack of knowledge of worker and inexistence of a poka-yoke system, on
12 of the reworked parts it was used a different carbon layer (240g/m2) than
the specified one (200g/m2).
– Reports of deviations during inventory of raw material + traceability records +
lab test results lead us to the serial number of the affected parts:
– 2019-99655
– 2019-99662
– 2019-99658
– 2019-99673
– 2019-99514
– 2019-99517
– 2019-99602
– 2019-99600
– 2019-99533
– 2019-99691
– 2019-99692
– 2019-99598
Production Dates : MAR 01, 2019 – MAR 01, 2019
Part 573 Safety Recall Report 22E-006 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Defect :
Description of the Defect : During a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets, 3
of the 4 tested samples failed on the penetration test.
FMVSS 1 : 218 – Motorcycle helmets
FMVSS 2 : NR
Description of the Safety Risk : In case of accident, safety of the motorcyclist is compromised (eventually
serious injury or death)
Description of the Cause : The cause for this noncompliance is related with the use (during a rework
process) of a different carbon layer (240g/m2) than the specified one (200g/
m2).
So, the problem is not related with the raw material itself.
Identification of Any Warning
that can Occur :
–
Involved Components :
Component Name : NR
Component Description : NR
Component Part Number : NR
Supplier Identification :
Component Manufacturer
Name : Nexxpro – Fábrica de Capacetes, S.A.
Address : Z.I. Amoreira da Gandara
Lote 11 Anadia Foreign States 3780-024
Country : Portugal
Chronology :
Once reported the failure detected during a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets
(dated 10 Sep 2020), it were picked some parts (of the same batch and also from another batch – 02) and
submitted to testing, in an external lab. All of the tested parts were conforming.
Details of the samples submitted to testing:
Part 573 Safety Recall Report 22E-006 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020 – batch 01
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020-1 – batch 02
It was requested info (S/N) regarding the S/N of the tested samples that failed. With those S/N it was possible
to find out part’s history.
According part’s history records, those 12 parts were all submitted to a rework process and, in all of them, it
was the same worker who proceeded with the rework and, at least in 11 of the 12 parts, a different raw
material (carbon layer) than the specified one was used, and so we do consider as potential affected parts the
12 described.
Description of Remedy :
Description of Remedy Program : Defect/noncompliance remedy program: some of the remaining parts –
same batch – were submitted to testing, with satisfactory results.
Registration of the raw material used on each manufacturing order is now
done through the IT system, and if a different Raw Material is used, the IT
system automatically issues a red alert, and the batch of the produced
parts is blocked.
Manufacturer’s plan for reimbursement: replacement by new helmets.
How Remedy Component Differs
from Recalled Component :
In the remedy component it was used the correct raw material (carbon
layer with 200g/m2).
Identify How/When Recall Condition
was Corrected in Production :
Recall condition was corrected on November’20.
Since this date, registration of the raw material used on each
manufacturing order is now done through the IT system, and if a different
Raw Material is used, the IT system automatically issues a red alert, and
the batch of the produced parts is blocked.
Moreover, it were checked all production records since mar’19, and part’s
history of all the produced helmets, and it weren’t found any deviations
related with wrongly raw material use.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 07, 2022 – MAR 18, 2022
Planned Owner Notification Date : MAR 23, 2022 – APR 02, 2022
Part 573 Safety Recall Report 22E-006 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-006
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Submission Date : JUL 31, 2023
NHTSA Recall No. : 22E-006
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Address : Zona Industrial Amoreira da Gandara
Lote 11 – Amoreira da Gandara –
Anadia Anadia 00 3780-024
Company phone : 231590010
Population :
Number of potentially involved : 12
Estimated percentage with defect : 67 %
Part 573 Safety Recall Report 22E-006 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Equipment Information :
Brand / Trade 1 : NEXX
Model : X.R2
Part No. : 01XR22312455100M
Size : M
Function : Safety
Descriptive Information : – On the 1st of march’19, it had been reported/detected a setup machine failure,
leading to 18 non-conforming products. Those parts were submitted to a rework
process.
– Due to lack of knowledge of worker and inexistence of a poka-yoke system, on
12 of the reworked parts it was used a different carbon layer (240g/m2) than
the specified one (200g/m2).
– Reports of deviations during inventory of raw material + traceability records +
lab test results lead us to the serial number of the affected parts:
– 2019-99655
– 2019-99662
– 2019-99658
– 2019-99673
– 2019-99514
– 2019-99517
– 2019-99602
– 2019-99600
– 2019-99533
– 2019-99691
– 2019-99692
– 2019-99598
Helmets with manufacturing date from January 2019 to May 2019
Production Dates : MAR 01, 2019 – MAR 01, 2019
Description of Defect :
Description of the Defect : During a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets, 3
of the 4 tested samples failed on the penetration test.
FMVSS 1 : 218 – Motorcycle helmets
FMVSS 2 : NR
Description of the Safety Risk : In case of accident, safety of the motorcyclist is compromised (eventually
serious injury or death)
Description of the Cause : The cause for this noncompliance is related with the use (during a rework
process) of a different carbon layer (240g/m2) than the specified one (200g/
Part 573 Safety Recall Report 22E-006 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
m2).
So, the problem is not related with the raw material itself.
Identification of Any Warning
that can Occur :
–
Involved Components :
Component Name : NR
Component Description : NR
Component Part Number : NR
Supplier Identification :
Component Manufacturer
Name : Nexxpro – Fábrica de Capacetes, S.A.
Address : Z.I. Amoreira da Gandara
Lote 11 Anadia Foreign States 3780-024
Country : Portugal
Chronology :
Once reported the failure detected during a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets
(dated 10 Sep 2020), it were picked some parts (of the same batch and also from another batch – 02) and
submitted to testing, in an external lab. All of the tested parts were conforming.
Details of the samples submitted to testing:
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020 – batch 01
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020-1 – batch 02
It was requested info (S/N) regarding the S/N of the tested samples that failed. With those S/N it was possible
to find out part’s history.
According part’s history records, those 12 parts were all submitted to a rework process and, in all of them, it
was the same worker who proceeded with the rework and, at least in 11 of the 12 parts, a different raw
material (carbon layer) than the specified one was used, and so we do consider as potential affected parts the
12 described.
Part 573 Safety Recall Report 22E-006 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Defect/noncompliance remedy program: some of the remaining parts –
same batch – were submitted to testing, with satisfactory results.
Registration of the raw material used on each manufacturing order is now
done through the IT system, and if a different Raw Material is used, the IT
system automatically issues a red alert, and the batch of the produced
parts is blocked.
Manufacturer’s plan for reimbursement: replacement by new helmets.
How Remedy Component Differs
from Recalled Component :
In the remedy component it was used the correct raw material (carbon
layer with 200g/m2).
Identify How/When Recall Condition
was Corrected in Production :
Recall condition was corrected on November’20.
Since this date, registration of the raw material used on each
manufacturing order is now done through the IT system, and if a different
Raw Material is used, the IT system automatically issues a red alert, and
the batch of the produced parts is blocked.
Moreover, it were checked all production records since mar’19, and part’s
history of all the produced helmets, and it weren’t found any deviations
related with wrongly raw material use.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 07, 2022 – MAR 18, 2022
Planned Owner Notification Date : JAN 01, 2023 – JUL 31, 2023
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Part 573 Safety Recall Report 22E-006 Page 5
The information contained in this report was submitted pursuant to 49 CFR §573
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-006
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Submission Date : JUL 17, 2022
NHTSA Recall No. : 22E-006
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Address : Zona Industrial Amoreira da Gandara
Lote 11 – Amoreira da Gandara –
Anadia Anadia 00 3780-024
Company phone : 231590010
Population :
Number of potentially involved : 12
Estimated percentage with defect : 67 %
Equipment Information :
Brand / Trade 1 : NEXX
Model : X.R2
Part No. : 01XR22312455100M
Size : M
Function : Safety
Descriptive Information : – On the 1st of march’19, it had been reported/detected a setup machine failure,
leading to 18 non-conforming products. Those parts were submitted to a rework
process.
– Due to lack of knowledge of worker and inexistence of a poka-yoke system, on
12 of the reworked parts it was used a different carbon layer (240g/m2) than
the specified one (200g/m2).
– Reports of deviations during inventory of raw material + traceability records +
lab test results lead us to the serial number of the affected parts:
– 2019-99655
– 2019-99662
– 2019-99658
– 2019-99673
– 2019-99514
– 2019-99517
– 2019-99602
– 2019-99600
– 2019-99533
– 2019-99691
– 2019-99692
– 2019-99598
Production Dates : MAR 01, 2019 – MAR 01, 2019
Part 573 Safety Recall Report 22E-006 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Defect :
Description of the Defect : During a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets, 3
of the 4 tested samples failed on the penetration test.
FMVSS 1 : 218 – Motorcycle helmets
FMVSS 2 : NR
Description of the Safety Risk : In case of accident, safety of the motorcyclist is compromised (eventually
serious injury or death)
Description of the Cause : The cause for this noncompliance is related with the use (during a rework
process) of a different carbon layer (240g/m2) than the specified one (200g/
m2).
So, the problem is not related with the raw material itself.
Identification of Any Warning
that can Occur :
–
Involved Components :
Component Name : NR
Component Description : NR
Component Part Number : NR
Supplier Identification :
Component Manufacturer
Name : Nexxpro – Fábrica de Capacetes, S.A.
Address : Z.I. Amoreira da Gandara
Lote 11 Anadia Foreign States 3780-024
Country : Portugal
Chronology :
Once reported the failure detected during a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets
(dated 10 Sep 2020), it were picked some parts (of the same batch and also from another batch – 02) and
submitted to testing, in an external lab. All of the tested parts were conforming.
Details of the samples submitted to testing:
Part 573 Safety Recall Report 22E-006 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020 – batch 01
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020-1 – batch 02
It was requested info (S/N) regarding the S/N of the tested samples that failed. With those S/N it was possible
to find out part’s history.
According part’s history records, those 12 parts were all submitted to a rework process and, in all of them, it
was the same worker who proceeded with the rework and, at least in 11 of the 12 parts, a different raw
material (carbon layer) than the specified one was used, and so we do consider as potential affected parts the
12 described.
Description of Remedy :
Description of Remedy Program : Defect/noncompliance remedy program: some of the remaining parts –
same batch – were submitted to testing, with satisfactory results.
Registration of the raw material used on each manufacturing order is now
done through the IT system, and if a different Raw Material is used, the IT
system automatically issues a red alert, and the batch of the produced
parts is blocked.
Manufacturer’s plan for reimbursement: replacement by new helmets.
How Remedy Component Differs
from Recalled Component :
In the remedy component it was used the correct raw material (carbon
layer with 200g/m2).
Identify How/When Recall Condition
was Corrected in Production :
Recall condition was corrected on November’20.
Since this date, registration of the raw material used on each
manufacturing order is now done through the IT system, and if a different
Raw Material is used, the IT system automatically issues a red alert, and
the batch of the produced parts is blocked.
Moreover, it were checked all production records since mar’19, and part’s
history of all the produced helmets, and it weren’t found any deviations
related with wrongly raw material use.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 07, 2022 – MAR 18, 2022
Planned Owner Notification Date : MAR 23, 2022 – SEP 23, 2022
Part 573 Safety Recall Report 22E-006 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-006
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Submission Date : FEB 03, 2022
NHTSA Recall No. : 22E-006
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Address : Zona Industrial Amoreira da Gandara
Lote 11 – Amoreira da Gandara –
Anadia Anadia 00 3780-024
Company phone : 231590010
Population :
Number of potentially involved : 12
Estimated percentage with defect : 67 %
Equipment Information :
Brand / Trade 1 : NEXX
Model : X.R2
Part No. : 01XR22312455100M
Size : M
Function : Safety
Descriptive Information : – On the 1st of march’19, it had been reported/detected a setup machine failure,
leading to 18 non-conforming products. Those parts were submitted to a rework
process.
– Due to lack of knowledge of worker and inexistence of a poka-yoke system, on
12 of the reworked parts it was used a different carbon layer (240g/m2) than
the specified one (200g/m2).
– Reports of deviations during inventory of raw material + traceability records +
lab test results lead us to the serial number of the affected parts:
– 2019-99655
– 2019-99662
– 2019-99658
– 2019-99673
– 2019-99514
– 2019-99517
– 2019-99602
– 2019-99600
– 2019-99533
– 2019-99691
– 2019-99692
– 2019-99598
Production Dates : MAR 01, 2019 – MAR 01, 2019
Part 573 Safety Recall Report 22E-006 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Defect :
Description of the Defect : During a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets, 3
of the 4 tested samples failed on the penetration test.
FMVSS 1 : 218 – Motorcycle helmets
FMVSS 2 : NR
Description of the Safety Risk : In case of accident, safety of the motorcyclist is compromised.
Description of the Cause : The cause for this noncompliance is related with the use (during a rework
process) of a different carbon layer (240g/m2) than the specified one (200g/
m2).
So, the problem is not related with the raw material itself.
Identification of Any Warning
that can Occur :
–
Involved Components :
Component Name : NR
Component Description : NR
Component Part Number : NR
Supplier Identification :
Component Manufacturer
Name : Nexxpro – Fábrica de Capacetes, S.A.
Address : Z.I. Amoreira da Gandara
Lote 11 Anadia Foreign States 3780-024
Country : Portugal
Chronology :
Once reported the failure detected during a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets,
it were picked some parts (of the same batch) and submitted to testing, in an external lab. All of the tested parts
were conforming.
It was requested info (S/N) regarding the S/N of the tested samples that failed. With those S/N it was possible
to find out part’s history.
Part 573 Safety Recall Report 22E-006 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
According part’s history records, those 12 parts were all submitted to a rework process and, in all of them, it
was the same worker who proceeded with the rework and, at least in 11 of the 12 parts, a different raw
material (carbon layer) than the specified one was used, and so we do consider as potential affected parts the
12 described.
Description of Remedy :
Description of Remedy Program : Defect/noncompliance remedy program: some of the remaining parts –
same batch – were submitted to testing, with satisfactory results.
Registration of the raw material used on each manufacturing order is now
done through the IT system, and if a different Raw Material is used, the IT
system automatically issues a red alert, and the batch of the produced
parts is blocked.
Manufacturer’s plan for reimbursement: replacement by new helmets.
How Remedy Component Differs
from Recalled Component :
In the remedy component it was used the correct raw material (carbon
layer with 200g/m2).
Identify How/When Recall Condition
was Corrected in Production :
Recall condition was corrected on November’20.
Since this date, registration of the raw material used on each
manufacturing order is now done through the IT system, and if a different
Raw Material is used, the IT system automatically issues a red alert, and
the batch of the produced parts is blocked.
Moreover, it were checked all production records since mar’19, and part’s
history of all the produced helmets, and it weren’t found any deviations
related with wrongly raw material use.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 07, 2022 – FEB 14, 2022
Planned Owner Notification Date : FEB 15, 2022 – MAR 22, 2022
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Part 573 Safety Recall Report 22E-006 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-006
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Submission Date : FEB 13, 2023
NHTSA Recall No. : 22E-006
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Address : Zona Industrial Amoreira da Gandara
Lote 11 – Amoreira da Gandara –
Anadia Anadia 00 3780-024
Company phone : 231590010
Population :
Number of potentially involved : 12
Estimated percentage with defect : 67 %
Equipment Information :
Brand / Trade 1 : NEXX
Model : X.R2
Part No. : 01XR22312455100M
Size : M
Function : Safety
Descriptive Information : – On the 1st of march’19, it had been reported/detected a setup machine failure,
leading to 18 non-conforming products. Those parts were submitted to a rework
process.
– Due to lack of knowledge of worker and inexistence of a poka-yoke system, on
12 of the reworked parts it was used a different carbon layer (240g/m2) than
the specified one (200g/m2).
– Reports of deviations during inventory of raw material + traceability records +
lab test results lead us to the serial number of the affected parts:
– 2019-99655
– 2019-99662
– 2019-99658
– 2019-99673
– 2019-99514
– 2019-99517
– 2019-99602
– 2019-99600
– 2019-99533
– 2019-99691
– 2019-99692
– 2019-99598
Production Dates : MAR 01, 2019 – MAR 01, 2019
Part 573 Safety Recall Report 22E-006 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Defect :
Description of the Defect : During a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets, 3
of the 4 tested samples failed on the penetration test.
FMVSS 1 : 218 – Motorcycle helmets
FMVSS 2 : NR
Description of the Safety Risk : In case of accident, safety of the motorcyclist is compromised (eventually
serious injury or death)
Description of the Cause : The cause for this noncompliance is related with the use (during a rework
process) of a different carbon layer (240g/m2) than the specified one (200g/
m2).
So, the problem is not related with the raw material itself.
Identification of Any Warning
that can Occur :
–
Involved Components :
Component Name : NR
Component Description : NR
Component Part Number : NR
Supplier Identification :
Component Manufacturer
Name : Nexxpro – Fábrica de Capacetes, S.A.
Address : Z.I. Amoreira da Gandara
Lote 11 Anadia Foreign States 3780-024
Country : Portugal
Chronology :
Once reported the failure detected during a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets
(dated 10 Sep 2020), it were picked some parts (of the same batch and also from another batch – 02) and
submitted to testing, in an external lab. All of the tested parts were conforming.
Details of the samples submitted to testing:
Part 573 Safety Recall Report 22E-006 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020 – batch 01
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020-1 – batch 02
It was requested info (S/N) regarding the S/N of the tested samples that failed. With those S/N it was possible
to find out part’s history.
According part’s history records, those 12 parts were all submitted to a rework process and, in all of them, it
was the same worker who proceeded with the rework and, at least in 11 of the 12 parts, a different raw
material (carbon layer) than the specified one was used, and so we do consider as potential affected parts the
12 described.
Description of Remedy :
Description of Remedy Program : Defect/noncompliance remedy program: some of the remaining parts –
same batch – were submitted to testing, with satisfactory results.
Registration of the raw material used on each manufacturing order is now
done through the IT system, and if a different Raw Material is used, the IT
system automatically issues a red alert, and the batch of the produced
parts is blocked.
Manufacturer’s plan for reimbursement: replacement by new helmets.
How Remedy Component Differs
from Recalled Component :
In the remedy component it was used the correct raw material (carbon
layer with 200g/m2).
Identify How/When Recall Condition
was Corrected in Production :
Recall condition was corrected on November’20.
Since this date, registration of the raw material used on each
manufacturing order is now done through the IT system, and if a different
Raw Material is used, the IT system automatically issues a red alert, and
the batch of the produced parts is blocked.
Moreover, it were checked all production records since mar’19, and part’s
history of all the produced helmets, and it weren’t found any deviations
related with wrongly raw material use.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 07, 2022 – MAR 18, 2022
Planned Owner Notification Date : JAN 01, 2023 – JUL 31, 2023
Part 573 Safety Recall Report 22E-006 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-006
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Submission Date : OCT 29, 2022
NHTSA Recall No. : 22E-006
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Address : Zona Industrial Amoreira da Gandara
Lote 11 – Amoreira da Gandara –
Anadia Anadia 00 3780-024
Company phone : 231590010
Population :
Number of potentially involved : 12
Estimated percentage with defect : 67 %
Equipment Information :
Brand / Trade 1 : NEXX
Model : X.R2
Part No. : 01XR22312455100M
Size : M
Function : Safety
Descriptive Information : – On the 1st of march’19, it had been reported/detected a setup machine failure,
leading to 18 non-conforming products. Those parts were submitted to a rework
process.
– Due to lack of knowledge of worker and inexistence of a poka-yoke system, on
12 of the reworked parts it was used a different carbon layer (240g/m2) than
the specified one (200g/m2).
– Reports of deviations during inventory of raw material + traceability records +
lab test results lead us to the serial number of the affected parts:
– 2019-99655
– 2019-99662
– 2019-99658
– 2019-99673
– 2019-99514
– 2019-99517
– 2019-99602
– 2019-99600
– 2019-99533
– 2019-99691
– 2019-99692
– 2019-99598
Production Dates : MAR 01, 2019 – MAR 01, 2019
Part 573 Safety Recall Report 22E-006 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Defect :
Description of the Defect : During a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets, 3
of the 4 tested samples failed on the penetration test.
FMVSS 1 : 218 – Motorcycle helmets
FMVSS 2 : NR
Description of the Safety Risk : In case of accident, safety of the motorcyclist is compromised (eventually
serious injury or death)
Description of the Cause : The cause for this noncompliance is related with the use (during a rework
process) of a different carbon layer (240g/m2) than the specified one (200g/
m2).
So, the problem is not related with the raw material itself.
Identification of Any Warning
that can Occur :
–
Involved Components :
Component Name : NR
Component Description : NR
Component Part Number : NR
Supplier Identification :
Component Manufacturer
Name : Nexxpro – Fábrica de Capacetes, S.A.
Address : Z.I. Amoreira da Gandara
Lote 11 Anadia Foreign States 3780-024
Country : Portugal
Chronology :
Once reported the failure detected during a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets
(dated 10 Sep 2020), it were picked some parts (of the same batch and also from another batch – 02) and
submitted to testing, in an external lab. All of the tested parts were conforming.
Details of the samples submitted to testing:
Part 573 Safety Recall Report 22E-006 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020 – batch 01
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020-1 – batch 02
It was requested info (S/N) regarding the S/N of the tested samples that failed. With those S/N it was possible
to find out part’s history.
According part’s history records, those 12 parts were all submitted to a rework process and, in all of them, it
was the same worker who proceeded with the rework and, at least in 11 of the 12 parts, a different raw
material (carbon layer) than the specified one was used, and so we do consider as potential affected parts the
12 described.
Description of Remedy :
Description of Remedy Program : Defect/noncompliance remedy program: some of the remaining parts –
same batch – were submitted to testing, with satisfactory results.
Registration of the raw material used on each manufacturing order is now
done through the IT system, and if a different Raw Material is used, the IT
system automatically issues a red alert, and the batch of the produced
parts is blocked.
Manufacturer’s plan for reimbursement: replacement by new helmets.
How Remedy Component Differs
from Recalled Component :
In the remedy component it was used the correct raw material (carbon
layer with 200g/m2).
Identify How/When Recall Condition
was Corrected in Production :
Recall condition was corrected on November’20.
Since this date, registration of the raw material used on each
manufacturing order is now done through the IT system, and if a different
Raw Material is used, the IT system automatically issues a red alert, and
the batch of the produced parts is blocked.
Moreover, it were checked all production records since mar’19, and part’s
history of all the produced helmets, and it weren’t found any deviations
related with wrongly raw material use.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 07, 2022 – MAR 18, 2022
Planned Owner Notification Date : MAR 23, 2022 – DEC 31, 2022
Part 573 Safety Recall Report 22E-006 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-006
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Submission Date : JUL 17, 2022
NHTSA Recall No. : 22E-006
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Nexxpro – Fabrica de Capacetes, S.A.
Address : Zona Industrial Amoreira da Gandara
Lote 11 – Amoreira da Gandara –
Anadia Anadia 00 3780-024
Company phone : 231590010
Population :
Number of potentially involved : 12
Estimated percentage with defect : 67 %
Equipment Information :
Brand / Trade 1 : NEXX
Model : X.R2
Part No. : 01XR22312455100M
Size : M
Function : Safety
Descriptive Information : – On the 1st of march’19, it had been reported/detected a setup machine failure,
leading to 18 non-conforming products. Those parts were submitted to a rework
process.
– Due to lack of knowledge of worker and inexistence of a poka-yoke system, on
12 of the reworked parts it was used a different carbon layer (240g/m2) than
the specified one (200g/m2).
– Reports of deviations during inventory of raw material + traceability records +
lab test results lead us to the serial number of the affected parts:
– 2019-99655
– 2019-99662
– 2019-99658
– 2019-99673
– 2019-99514
– 2019-99517
– 2019-99602
– 2019-99600
– 2019-99533
– 2019-99691
– 2019-99692
– 2019-99598
Production Dates : MAR 01, 2019 – MAR 01, 2019
Part 573 Safety Recall Report 22E-006 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Defect :
Description of the Defect : During a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets, 3
of the 4 tested samples failed on the penetration test.
FMVSS 1 : 218 – Motorcycle helmets
FMVSS 2 : NR
Description of the Safety Risk : In case of accident, safety of the motorcyclist is compromised (eventually
serious injury or death)
Description of the Cause : The cause for this noncompliance is related with the use (during a rework
process) of a different carbon layer (240g/m2) than the specified one (200g/
m2).
So, the problem is not related with the raw material itself.
Identification of Any Warning
that can Occur :
–
Involved Components :
Component Name : NR
Component Description : NR
Component Part Number : NR
Supplier Identification :
Component Manufacturer
Name : Nexxpro – Fábrica de Capacetes, S.A.
Address : Z.I. Amoreira da Gandara
Lote 11 Anadia Foreign States 3780-024
Country : Portugal
Chronology :
Once reported the failure detected during a Safety Compliance Testing for FMVSS No. 218 Motorcycle Helmets
(dated 10 Sep 2020), it were picked some parts (of the same batch and also from another batch – 02) and
submitted to testing, in an external lab. All of the tested parts were conforming.
Details of the samples submitted to testing:
Part 573 Safety Recall Report 22E-006 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020 – batch 01
– Laboratory: Omega (Italy); testing date: 02 Oct 2020; Report Nexxpro XR2 DOT 06102020-1 – batch 02
It was requested info (S/N) regarding the S/N of the tested samples that failed. With those S/N it was possible
to find out part’s history.
According part’s history records, those 12 parts were all submitted to a rework process and, in all of them, it
was the same worker who proceeded with the rework and, at least in 11 of the 12 parts, a different raw
material (carbon layer) than the specified one was used, and so we do consider as potential affected parts the
12 described.
Description of Remedy :
Description of Remedy Program : Defect/noncompliance remedy program: some of the remaining parts –
same batch – were submitted to testing, with satisfactory results.
Registration of the raw material used on each manufacturing order is now
done through the IT system, and if a different Raw Material is used, the IT
system automatically issues a red alert, and the batch of the produced
parts is blocked.
Manufacturer’s plan for reimbursement: replacement by new helmets.
How Remedy Component Differs
from Recalled Component :
In the remedy component it was used the correct raw material (carbon
layer with 200g/m2).
Identify How/When Recall Condition
was Corrected in Production :
Recall condition was corrected on November’20.
Since this date, registration of the raw material used on each
manufacturing order is now done through the IT system, and if a different
Raw Material is used, the IT system automatically issues a red alert, and
the batch of the produced parts is blocked.
Moreover, it were checked all production records since mar’19, and part’s
history of all the produced helmets, and it weren’t found any deviations
related with wrongly raw material use.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 07, 2022 – MAR 18, 2022
Planned Owner Notification Date : MAR 23, 2022 – SEP 23, 2022
Part 573 Safety Recall Report 22E-006 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

SEOCONTENT-END