HRL Laboratories reports that a new style of helmets using microlattice continues to be a top performer in NFL tests. They write:
For decades, football helmet construction has followed a standard model design. Hard case shell with foam interior. But VICIS, a leader in professional helmets knew there was room for innovation which led them into a creative partnership with a unique organization.
Source: HRL Laboratories
For decades, football helmet construction has followed a standard model design. Hard case shell with foam interior. But VICIS, a leader in professional helmets knew there was room for innovation which led them into a creative partnership with a unique organization.
For more than 70 years, scientists and engineers at HRL Laboratories have been on the leading edge of technology, conducting pioneering research, providing real-world technology solutions, and advancing the state of the art.
HRL had already been exploring a novel cellular architecture as part of a government project to improve soldier protective systems.
The result? Microlattice.
Source: HRL Laboratories
Microlattice is a structure that provides superior shock absorption versus the traditional foam structure used in protective gear such as helmets.
• A published study demonstrated that microlattice has up to 27% more energy absorption efficiency than expanded polystyrene (EPS) foam, the type typically found in bike helmets, when sustaining a single impact.
• And, up to 48% improved absorption efficiency over the state-of-the-art vinyl nitrile foam, the type found in some football helmets, when impacted repeatedly.
• The structure of the microlattice can be tuned to absorb energy under different impact conditions.
Improved comfort design and Air Flow
• The open-cell architected structure of the microlattice, resembling the Eiffel Tower, allows air to flow freely through the entire pad. This unique feature improves air flow for a much cooler wearing experience.
• This contrasts with traditional helmets that use closed-cell foam padding, which tends to trap heat and sweat against the wearer’s head
Innovative Manufacturing Process
• HRL uses a unique process which involves projecting UV light through a patterned template onto a tray of specially formulated liquid resin.
With light casting, a set of pads for a helmet can be produced in just a few minutes, whereas traditional methods can take several hours longer.
Real-world applications
When VICIS heard about microlattice and its special properties, they immediately envisioned its application in the world of professional football. As part of their ongoing collaboration with the National Football League (NFL), VICIS was looking to improve impact mitigation while also maximizing player comfort.
Could microlattice be the answer?
VICIS produced sample helmets for the NFL that leveraged the new material and submitted them to the NFL for testing.
• The new style of helmets with microlattice continue to be top performing in NFL tests.
• In addition to the shock absorption qualities, microlattice is more comfortable to wear for athletes as it’s inherently more breathable and lighter weight than foam.
VICIS and HRL have since worked together in incorporating the microlattice designs into the VICIS professional helmet series under the technology name Matrix.
In fact, in the 2023/24 football season, all NFL teams purchased helmets with this improved shock absorption technology.
This creative collaboration across different industries sparked a revolution in football helmet technology.
