Thermoplastic matrix combat helmet with carbon-epoxy skin for ballistic performance

Abstract This chapter describes a new class of ballistic materials and process developments to enhance the ballistic performance and reduce the weight of ballistic helmets. A brief description of the Personnel Armor System Ground Troop helmet is included to illustrate that the technology known since 1970 to assemble ballistic helmets has not changed for the past 45 years, and improvements in ballistic protection have been associated with new and superior ballistic materials. Examples are included to demonstrate that ultra-high molecular weight polyethylene fibers when combined with a thermoplastic matrix improve the ballistic performance of helmets beyond that afforded by the incumbent para-aramid fiber PVB-phenolic resin composite system. To develop a lightweight thermoplastic matrix composite helmet, INTER Materials describes a patent-pending helmet design that increases the overall ballistic performance by 70–80% using a low-cost and high-volume manufacturing process.