Ballistic helmet materials and the process of manufacturing ballistic helmets has Ballistic helmet materials and production processes have evolved drastically since their first creation. From metal fabrication, fibers, and ceramics - modern-day ballistic helmets are made up of numerous different components; herein we explore these innovations as well as what their future may hold.
Some of the earliest ballistic helmets on the "modern day" battlefield can be seen during WWI. Long before advanced fiber manufacturing techniques, the ballistic helmets, and other armor were made out of metal, much like you would find on ancient battlefields. While the metalworking processes were much-improved at this point, their weight made them mostly impractical for anything other than stationary fighting. These metal helmets would prove to be the norm, with increases in ballistic capability and decreases in their weight until the late 20th century. In the 1980's ballistic materials such as Kevlar and aramid would be implemented to improve the ballistic protection and of course weight.
Kevlar has become the go-to material for clothing, accessories and ballistic weapons more than any other modern material. When it comes to ballistic helmets, Kevlar fiber was first utilized in the Ground Forces Personnel Armor System (PASGT) helmet in 1993 before later making an appearance in 2003 for Advanced Combat Helmet (ACH) use; this version can absorb 20% more kinetic energy than PASGT helmet. Furthermore, this material can also be found in Advanced Combat Vehicle Crew helmets known as CVC helmets
Ultra-high molecular-weight polyethylene (UHMWPE, UHMW) is another material frequently utilized in ballistic helmets, often known by its brand names Dyneema or Spectra. At present, many bullet-proof product companies in the industry - us included! - employ some form of UHMWPE fiber in bullet-proof helmet products due to its weight savings compared with aramid which typically amounts to 20-30% savings at equal levels of protection.
What lies ahead for ballistic helmet manufacturing?
Many experts anticipate fiber improvements to remain an important focus; these strands can be mixed to form unique blends, as evidenced by the U.S Army investing over one million dollars into genetically engineered spider silk with hopes that its energy absorption capabilities could outstrip Kevlar; while others believe advances may come in form of "next generation metals" with better ballistic properties and lighter weight properties; either way, we have come a long way since boar's tusks were the only protection available!
