What's In Your Ballistic Helmet?

The tactical gear community has seen a plethora of editorials focusing on ballistic helmets, particularly on the accessories that enhance their functionality. However, discussions on comfort, specifically the padding and retention systems that keep helmets secure, have often been overlooked. At Hard Head Veterans, we've always aimed to dissect both the strengths and weaknesses of helmets from past to present. Let's face it—an uncomfortable helmet is simply unbearable. Based on our firsthand experiences, we're here to outline what to avoid when it comes to helmet comfort. This guide is for those new to the tactical helmet market, offering a starting point, though we don't claim to be the definitive source on what's "the best." We have our opinions, and we believe they carry some weight.

 

The Journey from PASGT to Modern Combat Helmets

Before the era of advanced materials like memory foam, high-density padding, and 3D printed micro lattice systems, military personnel were issued the standard K-Pot helmet, held in place by nothing more than nylon webbing and an infamously uncomfortable sweatband. These helmets were typically not new; they were often recycled with minimal quality control, passing on years of accumulated wear and "head funk" from previous users.

 

PASGT Helmet Design Flaws and Practical Shortcomings

The PASGT (Personnel Armor System for Ground Troops) helmet was once the go-to headgear for combat, featuring an interior of nylon webbing designed to suspend the helmet off the wearer's head. However, this webbing was notoriously short-lived, losing its form and integrity after just one or two field operations, leading to issues with odor and proper helmet fit.

Training for combat involves replicating battlefield conditions, where the PASGT's design proved to be extremely problematic. Its bulk and simple two-point chin strap system made achieving a stable prone shooting position almost impossible. The large brim, intended to offer additional coverage and protection, instead often resulted in the helmet obscuring vision or even causing injury by smashing into the bridge of the nose due to improper helmet retention during rapid movements.

Budget Over Comfort – The Helmet Sweatband and Chinstrap Conundrum

When it comes to the sweatband, the PASGT helmet's approach was less than ideal, using a small 2x4 inch strip of "leather" with foam meant to absorb sweat. Instead, after just a few hours of field use, it transformed into an abrasive, bacteria-laden nightmare, chafing the skin and fostering microbial growth while offering up a pungent smell that most of us will never forget. The foam's degradation left wearers with hard, protruding edges that dug into the skull, far from being a comfort feature. Not only did this design fail in providing comfort, but it also created multiple hot spots around the head, making the helmet itself a chore to wear for extended periods of time.  

Last comes the chinstrap, an area where the PASGT helmet often disappointed us. If we were lucky, we'd get a helmet from CIF with a stabilizing plastic cup attached to the nylon web strap. However, more often than not, luck wasn't on our side, and we’d end up with helmets using just the same rough ½ inch nylon webbing for the chinstrap, without any chin cup. This setup not only caused painful chafing on the chin and neck but was also completely ineffective, severely undermining stability and making the use of night vision systems nearly impossible. 

 

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Helmet Tech Evolution: From 2025 to the Future

During the height of the Global War on Terror, it became clear that the PASGT system, designed before Desert Storm in the 1990s, was inadequate for modern combat applications. Helmets have evolved significantly since that time. Check out this article on the evolution of combat helmets for more detail. The first major evolutions were the Light Weight Helmet System (LWH) and the Modular Integrated Communications Helmet (MICH).

These systems were developed by experts who understand the profound physical and mental impacts of war on the human body. These experts quickly identified the shortcomings of older helmet standards, leading to new designs focused on improving head protection to reduce Traumatic Brain Injury (TBI) and fatal head injuries on the battlefield. How have these changes impacted soldiers on the ground? Let's delve into the specifics of these advancements.

The Rise of the LWH and MICH Combat Helmets

During the Global War on Terror, the inadequacies of the PASGT helmet became glaringly apparent, leading to the development of more advanced head protection systems. The Lightweight Helmet (LWH), primarily adopted by the U.S. Marine Corps, was designed to provide better comfort and protection than its predecessor. Its introduction marked a significant step forward with features like an improved four-point retention system and a redesigned liner, offering less weight and more comfort without compromising on protection.

Similarly, the Modular Integrated Communications Helmet (MICH), initially developed for special operations forces, soon found widespread use across different branches of the U.S. military. The MICH's design focused on compatibility with communication equipment, offering a higher cut for better visibility and hearing, and it incorporated advanced Kevlar for enhanced ballistic protection against handgun rounds. These helmets represented a shift towards more specialized and adaptable headgear, tailored to the diverse and demanding environments of modern warfare.

The rise of the LWH and MICH during the Global War on Terror wasn't just about improving physical protection; it was equally about addressing the operational needs of soldiers in highly varied combat scenarios. The LWH's design retained the familiar PASGT profile but was lighter, offering increased protection while being more comfortable for extended wear. The MICH, on the other hand, introduced innovations like a pad system in place of the traditional sling suspension, which provided better impact protection and comfort. Both helmets were part of a broader trend towards modularity and user customization, allowing for the attachment of night vision devices, communication headsets, and other tactical accessories without compromising the helmet's integrity.

Modern Helmet Design Standards

The evolution of helmet technology has been significantly shaped by lessons learned from past designs, leading to the establishment of industry standards that prioritize both safety and user comfort. These standards have been driven by the collective experience of manufacturers, military and law enforcement feedback, and advancements in material science. Today, helmet manufacturers like HHV, Avon Rubber, and Gentex have developed proprietary helmet shells, padding and suspension systems that adhere to, or often exceed, these modern benchmarks:

There is a standard that formed within the industry driven by many of the pitfalls that we have mentioned here. Companies who have brought proven gear to market have all come with their own branded padding and suspension systems. All of which include the following:

  • Modularity: Helmets now commonly feature Velcro attachments, allowing for the easy integration of accessories like cameras, communication gear, and IFF marking systems. This modularity ensures that helmets can be customized to meet the specific needs of various missions, enhancing operational effectiveness without sacrificing protection or comfort.
  • Hygiene and Comfort: The use of moisture-wicking materials in padding has become standard, designed to keep the interior environment dry and reduce the risk of bacterial growth, which was a significant issue with older helmet designs. This not only improves comfort but also extends the lifespan of the helmet by maintaining its hygienic condition.
  • Ergonomic Design: The days of one-size-fits-all, blocky padding are largely behind us. Modern helmets come with form-fitting padding tailored to the contours of the human head, providing a snug yet comfortable fit. This ergonomic approach reduces pressure points, enhances stability, and improves overall wearability during extended operations.
  • Impact Resistance: Helmets are now engineered to exceed the Advanced Combat Helmet (ACH) blunt impact standards as detailed in AR/PD 10-02, ensuring they can withstand severe impacts without transferring excessive force to the wearer's head, thus reducing the risk of traumatic brain injuries.

  • Deformation Limits: A focus on minimizing backface deformation has become crucial. Current designs aim to limit this to less than 24mm, ensuring that the helmet's interior does not intrude upon the head space in a way that could cause injury upon impact.
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The Role of Industry Leaders in Helmet Innovation

At Hard Head Veterans (HHV), we're pushing the boundaries of helmet technology with innovations like our A3S Lite Shroud for lightweight night vision integration and our M-LOK rails, which offer a versatile platform for secure accessory attachment. Additionally, our micro lattice padding system represents a significant advancement, providing unmatched comfort and impact protection by conforming to the user's head shape and reducing backface deformation. These developments underscore our role in leading the industry towards helmets that are not only safer but also more functional and user-friendly.

In this constantly evolving field of head protection, companies like Hard Head Veterans, Avon Protection, Gentex and a host of other manufacturers play a critical role in the innovation of the head borne systems. Their contributions, alongside those from HHV, ensure a competitive environment that drives continuous improvement in helmet design, focusing on comfort, safety, and adaptability to meet the evolving needs of the warfighter.

The Future of Tactical Helmet Systems

The rapid evolution of helmet technology over the last decade suggests that we are on the cusp of even more groundbreaking advancements. From the outdated PASGT to today's advanced over-the-ear designs, we've witnessed a transformation in both the design and functionality of ballistic helmets, focusing not just on protection but also on wearer comfort and adaptability.

Anticipating Future Innovations – A Manufacturer’s Perspective

As a manufacturer deeply invested in the evolution of tactical helmets, we at Hard Head Veterans (HHV) are not just observing but actively shaping the future of helmet technology. We anticipate several key areas where innovation will lead to significant advancements in the functionality, comfort, and safety of ballistic helmets:

  • Customization and Comfort: Future helmets will likely offer even more personalized fit options, through adaptive technologies or 3D printing, ensuring each helmet is tailored to the individual's head shape for maximum comfort and effectiveness. As a manufacturer, we are already providing this technology with our DLS 3D printed Micro Lattice helmet padding system, which is a technology that is still in its infancy.
  • Material Science: Expect breakthroughs in materials like graphene or advanced composites, leading to helmets that are lighter, more durable, and better at dissipating impact energy while maintaining or even enhancing protective capabilities. Some systems, like our rifle rated helmet up-armor plates, are already starting to be widely adopted and used in the law enforcement world.
  • Smart Helmets and Beyond: With the integration of technology and the proliferation of drones on the modern battlefield, we will see helmets with built-in augmented reality for enhanced battlefield awareness, sensors for monitoring health metrics, or even systems for real-time language translation, turning helmets into multifunctional tactical tools. IVAS, an augmented reality system built by Microsoft is already beginning field tests.
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Upgrading Existing Gear

For those still using older systems like the MICH, consider upgrading your helmet's retention system to something like our fidlock retention system for better fit and stability. If you're stuck with outdated padding like the MSA block foam, upgrading to modern solutions like the HHV Comfort Plus Helmet Pad System or Micro Lattice helmet pads can significantly enhance comfort and safety. These upgrades not only improve the helmet's comfort but also increase its resistance to blunt force impacts, making the helmet a better tool for protecting your head. Either of these upgrades are possible with your older system, helping you achieve a more modern helmet on a tight budget.

In conclusion, the journey from the rudimentary K-Pot and PASGT helmets to the sophisticated systems of today highlights a relentless pursuit of safety, comfort, and operational efficiency in helmet technology. Hard Head Veterans has been at the forefront, innovating with our magnetic chinstrap fidlock suspension system and our innovative micro lattice padding system.

As we look to the future, expect even more innovations to improve the inside of your helmet system. Whether you're upgrading from older model helmets or seeking the latest innovations, we invite you to stay connected with us here at Hard Head Veterans by following us on any of our social media platforms linked at the bottom of this page.