Mrmagloo...There's really no way to answer your question fully. There are simply too many variables involved. Certainly, if you wore a helmet a few times a year, kept it stored in a dry, temperature regulated environment, never sweated inside the helmet, etc...it would likely last longer than 5 years. Snell recommends every 5 years...that's a statistical "average" based on their testing methodology. If you wear a helmet almost every day, they recommend replacement every 3 years. This is the quote from the Snell Foundation:
The five-year replacement recommendation is based on a consensus by both helmet manufacturers and the Snell Foundation. Glues, resins and other materials used in helmet production can affect liner materials. Hair oils, body fluids and cosmetics, as well as normal "wear and tear" all contribute to helmet degradation. Petroleum based products present in cleaners, paints, fuels and other commonly encountered materials may also degrade materials used in many helmets possibly degrading performance. Additionally, experience indicates there will be a noticeable improvement in the protective characteristic of helmets over a five-year period due to advances in materials, designs, production methods and the standards. Thus, the recommendation for five-year helmet replacement is a judgment call stemming from a prudent safety philosophy.
And this is from the Webikeworld site:
It's difficult to know exactly when a helmet should be replaced and there are varying opinions on this topic. Some helmet manufacturers (e.g., Shoei) provide a free inspection service where you can send the helmet to their representatives for a free inspection.
Rule of thumb is generally around a 5 year max life expectancy, but this can depend on usage, wear or helmet quality. Also, helmet technology, styling and comfort features change fairly regularly over time, so 5 years would be about max for me anyway and at that point, I'd consider buying a new helmet.
For example, my Arai Quantum II was my regular "go to" helmet but after 4 years it started to look a bit seedy and the liner felt like it was becoming compressed, so I replaced it even though it had never been dropped or damaged.
If the helmet has been dropped or if it is damaged from chips, cracks, etc. on the outside, then it may need replacement. But the most important part is the liner and especially the EPS. The EPS balls deflate on impact, essentially giving up their life to dissipate energy. If the EPS is at all damaged, compressed or feels loose, it is definitely time for a new helmet.
Want more? We asked Shoei about the "5-year helmet life" rule and here's what they told us: "The service life on our helmets is five years from purchase date or seven years from manufacture date, whichever comes first. The warranty covers the helmet for the same period.
Glues, resins and other materials used in helmet production can affect liner materials. Hair oils, body fluids and cosmetics, as well as normal "wear and tear" all contribute to helmet degradation.
Petroleum-based products present in cleaners, paints, fuels and other commonly encountered materials may also degrade materials used in many helmets possibly degrading performance.
Additionally, experience indicates there will be a noticeable improvement in the protective characteristic of helmets over a five-year period due to advances in materials, designs, production methods and the standards.
Thus, the recommendation (for 5 year) helmet replacement is a judgment call stemming from a prudent safety philosophy."
Says basically the same thing. Although the Snell Foundation is paid to test helmets for manufacturers, from my understanding the fees are the same for all, so that leads me to believe that the testing is about as unbiased as it could be.
So...the answer is: It Depends. Not being a smart azz, but my 5 year old computer may still work, but can a new and improved version do a "BETTER" job? In all probability. So, advances in technology would probably pursuade me to purchase a new helmet at least every 5 years, if for no other reason than to get something lighter, better ventilated, better visual characteristics, etc. But I doubt seriously if my helmet is REALLY worn out after 5 years...but I'm tired of it and want a new one, so I get one, if money allows.