The present research aims to develop a novel technique for the creation of composite riot helmet shells with reinforcing fibre continuity for better protection against low velocity impacts. In this research an innovative, simple and effective method of making a single-piece continuous textile reinforced helmet shell using vacuum bagging has been established and discussed. This technique also includes the development of solid collapsible moulding apparatus from nonwoven fibres. Angle-interlock fabric, due to its good mouldability, low shear rigidity and ease of production is used in this research. Several wrinkle-free single-piece composite helmet shells have been manufactured.Low-velocity impact tests on the continuously reinforced helmet shells have been carried out. For this purpose an in-house helmet shell testing facility has been developed. A test rig has been designed in such a way that the impact test can be carried out at different locations on the riot helmet shell. Low-velocity impact testing has been successfully conducted on the developed test rig. Practical experimentation and analysis revealed that the helmet shell performance against impact is dependent on the impact location. The helmet shell top surface has better impact protection as compared to the helmet shell side and back locations. Moreover, the helmet shell side is the most at risk location for the wearer. Finite Element models were created and simulated in Abaqus software to investigate the impact performance of single-piece helmet shells at different impact locations. Model parts have been designed in Rhinoceros software. Simulated results are validated by the experimental results which show that the helmet top position is the safest position against an impact when it is compared to the helmet back and helmet side positions.