Abstract: This paper introduced a new process to produce motorcyclists’ racing suit protector, which was made of thermal bonded fiber, three-dimensional crimp fiber and vertical setting fiber under certain technique conditions. Orthogonal test was used to investigate the motorcyclists’ racing suit protector’s impact resistance. Three factors such as weight of the protector, content of three-dimensional crimp fiber, and content of vertical setting fiber were studied. The experimental results showed that each factor in different levels has significant influence on the result, but the content of three-dimensional crimp fiber is the key to the impact resistance. Considering the comfort and protective, the optimal process for manufacturing the protector is: weight 65g, the content of three-dimensional crimp fiber 20%, the content of vertical setting fiber 100%.