Adept Armor provides combat helmets and body armor systems for military and law enforcement personnel, including the NovaSteel™ helmet, one of the world’s toughest ballistic helmets.
The development of combat helmets has progressed significantly from the original steel M1 helmet used in the mid-20th century to modern designs, reflecting advances in materials and technology.
Understanding the ballistic capabilities of these helmets is crucial for evaluating their effectiveness in the field, and advancing technology for the future.
M1 Steel Helmet
The M1 steel helmet served as the standard-issue for US soldiers for decades, primarily designed for protection against shrapnel rather than small arms fire. Despite its limitations, it remained in service until the early 1980s. Notably, the M1’s performance against handgun threats was objectively poor, particularly when compared to contemporary standards.
Transition to Modern Materials
Beginning in the 1960s, the military sought to replace the M1 with improved materials. While various options like titanium alloys and polycarbonate were explored, none provided a substantial upgrade over the M1’s Hadfield steel. Fiberglass helmets demonstrated better ballistic properties but lacked durability, particularly in saltwater environments.
In the late 1960s, Brigadier General George Hayes initiated a project to develop a nylon-laminate helmet, known as the Hayes-Stewart helmet. However, its ballistic performance did not exceed that of the M1, leading to its discontinuation in 1972.
Learn more about the Adept NovaSteel™ helmet >>
Introduction of Kevlar® Helmets
The turning point came with the introduction of Kevlar® 29, a high-modulus polymer fiber significantly stronger than previous materials. Helmets made from Kevlar were developed under the PASGT program, which was issued to troops in 1983. The PASGT offered improved performance against fragment-simulating projectiles (FSPs) and demonstrated capabilities against 9mm FMJ ammunition, although it was notably heavier than the M1.
Despite the improvements, the PASGT helmet remained incapable of reliably stopping rifle rounds, a limitation echoed in subsequent designs.
Advancements with the ACH and MICH
The Modular Integrated Communication Helmet (MICH) was developed to address the shortcomings of the PASGT by removing the brim and optimizing the design for communications gear. It was slightly lighter and featured enhanced padding. The Advanced Combat Helmet (ACH) evolved from the MICH and included specifications to stop 9mm FMJ at specific velocities, with improved performance against fragments.
Both the ACH and MICH continued to face limitations against rifle threats, as highlighted by reports indicating their vulnerability to high-velocity rounds commonly encountered in combat scenarios.
The Enhanced Combat Helmet (ECH)
Initiated in 2009, the ECH aimed to provide superior protection against fragmentation and certain rifle threats while maintaining the weight of the ACH. Made from ultra-high molecular weight polyethylene (UHMWPE), the ECH outperformed the ACH against specified threats, yet the high cost and concerns regarding backface deformation led to mixed reviews regarding its overall effectiveness.
IHPS helmet with multicam cover
IHPS and Future Developments
The Integrated Head Protection System (IHPS) is currently being developed as a replacement for the ACH, incorporating features from the ECH and providing similar ballistic capabilities. However, both the ECH and IHPS are limited in their ability to stop steel-core projectiles, which are standard in modern military ammunition.
Performance Limitations and Future Directions
While current helmets like the ECH and IHPS offer improved protection against certain threats, they are not designed to withstand the penetrative power of steel-core rounds, including common military ammunition. This presents a significant gap in protective capabilities.
In contrast, a modernized steel helmet—such as the Adept NovaSteel—offers a viable solution. Were the M1 made heavier and produced from a modern steel alloy, it stands to reason that its protective capabilities could have kept pace at a lower cost. The Adept NovaSteel helmet is lighter than the PASGT and provides superior performance against both fragments and handgun rounds.
The evolution of combat helmets reflects ongoing advancements in materials science and design. As technology progresses, the focus will likely shift toward helmets that can stop a wider range of threats, including steel-core projectiles, while minimizing backface deformation. Future developments promise to enhance soldier protection in increasingly complex combat environments.
