The primary aim of our project is to increase the safety of helmet users and also to reduce the usage of plastic. This led us to the idea of BIO-COMPOSITE HELMET. Generally, bio-composite materials are synthesized using natural fibers as reinforcements together with matrix due to their low density with high specific mechanical strength, availability, renewability, degradability. The present work attempts to make an improvement in the existing helmet manufacturing process. The materials that are used have better mechanical properties in order to enhance the compatibility between fibers and the matrix. The biocomposites are prepared using unsaturated polyester matrix and fibers such as coconut coir and areca using hand lay-up method with appropriate proportions to result in helmet shell structure. The fabricated helmets will be evaluated for their mechanical properties such as hardness, impact strength, and compression strength. Thus, we constructed bio-composite helmets that have highly strong and environmentally friendly.