A new standard for high performance industrial safety helmets, EN14052, requires double the energy absorption of helmets manufactured to the existing standard. Current helmets are typically injection moulded UV stabilised HDPE.

Self-reinforced polypropylene helmet shells have been manufactured to enhance the energy absorption characteristics of the shell without increasing the helmet weight.

3mm thick helmet shells have been produced from four different types of self-reinforced polypropylene materials – Curv, Armordon, MFT and Pure – using matched aluminium tooling in a stamp forming process.

The deep draw of the helmet shape demonstrates the formability of self-reinforced plastics under robust, controlled moulding conditions.

Application-specific testing highlighted the high impact performance of the material at low temperatures, as well as the light weight of the helmet shell.

Moulded self reinforced plastic helmets are a viable alternative to the current production solutions. Higher impact performance and reduced weight mean that a higher performance safety helmet, able to meet the tough EN14052 standard, can be achieved with this material.

- Undertaken in collaboration with JSP