1. Current Sports Helmet Design
The mandated use of helmets in organized sports dates back as early as the 1940’s when the National Collegiate Athletic Association (NCAA) and National Football League (NFL) made helmets a requirement for players to reduce head-related injuries
[1]. Since this time, multiple organizations have developed standards for testing and producing sports helmets. While the implementation of sports helmets has successfully reduced catastrophic head-related injuries, including traumatic brain injuries (TBI) and orofacial injuries, the risk of concussive injuries remains unmitigated. This discrepancy in selective protection may be explained by how helmets are tested and certified, with the current standard for testing helmets focusing on the use of linear acceleration, which has demonstrated a reduction of TBI and skull fractures, but not concussive injury
[2]. Research has demonstrated that the primary mechanism of injury leading to concussions in sports is the result of rotational acceleration, which is not explicitly tested for by certifying organizations
[3][4].
Current sports helmets are designed to protect against punches, falls, projectiles, collisions, and abrasion, and can be grossly organized into two main categories—single-impact and multi-impact helmets
[5]. However, virtually all current sports helmets have the basic design of an inner comfort liner, an impact energy attenuating liner, a restraint system, and an outer shell
[6]. Single-impact helmets are designed to withstand high-impact encounters only once. Examples of these include bicycle, mountaineering, and equestrian helmets. The energy attenuating liner in these helmets is typically constructed of lightweight expanded polystyrene (EPS) foam, which does well in dissipating energy, but permanently deforms after impact
[1]. On the other hand, multi-impact helmets are designed to withstand multiple impacts and are used in US football, hockey, motorcross, and rugby. The resilience to multiple impacts is accomplished by construction with either vinyl nitrile (VN) or expanded polypropylene (EPP) foam for the energy attenuating liner. VN and EPP can return to their original form after impact; however, VN performs better with lower energy impacts than EPP, which performs better at higher energy impacts
[1][7]. In both helmets, the outer shell functions to distribute the force of impact along the area of the energy attenuating liner. Shells are commonly constructed of polycarbonate (PC) or ABS plastic, but some helmets may have hard shells composed of composites, such as fiberglass or carbon fiber
[8][9].
Further variations in helmet design exist according to the dangers encountered in each sport, as well as practicality, ease of use, and aesthetics. Sports (e.g., lacrosse, hockey, and baseball) where the impact from a projectile is of concern may implement a face guard (typically either a wired frame or an extension of the helmet’s shell) to protect against orofacial injuries
[10][11]. Cycling and mountaineering helmets are often engineered to be highly aerodynamic and as light as possible to avoid hindering the user’s performance
[12]. Helmets used in motorcycle-variant sports are designed with thicker protective layers that aerodynamically encapsulate the entire head to protect against greater risks associated with high speed
[13].
2. Current Military Helmet Design
The current issue US military helmet for combat use is the advanced combat helmet (ACH), and previously was the personnel armor system for ground troops (PASGT) in the late 1990’ and early 2000s
[14]. Prior work has highlighted the blunt impact standard limitation to linear head acceleration
[15], with the need to focus on rotational head motion, the likely mechanism contributing to diffuse axonal injury (DAI)
[15][16][17][18]. Military specification (mil-spec) requires a blunt impact acceleration limit testing for pass/fail criteria of the ACH, but does not require rotational component testing
[17]. Blast-induced TBI (BTBI) is also a mechanism of combat-induced diffuse axonal injury where blast waves cause rotational forces on the brain to induce DAI.
The ACH is equipped with high-strength Kevlar 129 fibers, housed in a 7.8 mm thick composite shell
[19][20]. Previous literature has highlighted the efficacy of the ACH head protection in reduced likelihood of blast-induced mild TBI (mTBI), where levels of protection increase with peak blast exposure
[17], as well as protection against blast-induced intracranial pressure (ICP) increases and brain strains
[21][22]. Although there is increased overall protection against blast exposures, helmet design still has limitations. For example, Zhang et al.
[21] demonstrated that blast waves could directly penetrate through the gap between the forehead and the helmet, causing further deformation of padding.
Warfighters who engage in parachute combat rather than ground combat are twice as likely to sustain any form of TBI
[23] and are three times more likely to sustain a mild form of a TBI wearing the PASGT combat helmet compared to the ACH
[23]. This is likely due to the higher velocity impacts sustained in parachute jumping and a suspension system that is not as advanced as the ACH. The current ACH uses a suspension padding system that offers protection against axonal shearing, but the preclinical models are still limited regarding how effective these padding systems are in humans
[16].
Thus, slight modifications to the ACH and/or future helmet design mil-spec testing may reduce the incidence of DAI and the prevalence of military-related TBI for warfighters. Preclinical animal models may provide further adequate preliminary evidence of the need to address diffuse rotational injury associated with warfighters.
3. Current Construction Helmet Design
In the United States, the construction industry is responsible for the largest portion of industrial injuries and induces an estimated healthcare and economic burden of $11.5 billion in direct medical costs and lost wages, as last investigated in 2002
[24]. The United States Bureau of Labor Statistics reports that falls in the construction industry account for 62.9% of all fatal falls
[25]. Industrial workers 65 years of age and older are at the greatest risk for more severe outcomes after TBI, including death. In addition, this age group has a higher incidence of falls, and within the construction industry, these workers have the highest (57%) frequency of fall-related injuries, including TBIs. This increased risk for injury demonstrates the importance of proper personal protective equipment (PPE), such as helmets. PPE is defined as a control measure used in hazardous situations where the hazard cannot be eliminated or controlled to an acceptable level through engineering design or administrative actions
[26]. According to Occupational Safety and Health Administration (OSHA) and the United States Army Corps of Engineers (USACE) regulations, all employees and visitors to a construction site must wear a provided hard hat
[26]. These industrial safety helmets are required in conditions where objects might fall from above and strike workers on the head, workers may bump their heads against objects, or there is possible contact with electrical hazards. The American National Standards Institute (ANSI) regulates hard hats by setting performance and requirement testing standards. Type I and II helmets reduce force to the top of the head, while type III classified helmets can reduce impact to the top and sides of the head. Industrial safety helmets have a suspension design that is intended to reduce the force of impact and penetrations of small objects. Furthermore, a study was performed to assess their effectiveness against larger objects and found these helmets were capable of reducing the force and linear acceleration for vertical impact
[25][26][27]. They also reduced the likelihood of skull fracture and severe injury, further supporting the importance of industrial safety helmets.
Construction-related injuries to the head can result in skull fractures and localized underlying brain injury, closed head injuries, neck injuries, and rotational injuries leading to diffuse axonal injury
[28]. A study was performed to assess the impact of hard hats during varied neck movements utilizing surface electromyography sensors on the upper trapezius muscles of volunteer subjects
[29]. The researchers demonstrated that muscle activity and fatigue were not increased while wearing an industrial hard hat, suggesting that this protective equipment is not causing further detriment to workers’ neck strain
[29]. Vertical impact occurs in 36% of falling object cases, yet most injuries include a rotational injury
[28]. Though industrial safety helmets are required PPE in the construction industry, these helmets have suspension designs that primarily protect against vertical impact. This design may be beneficial for many types of possible injury at a construction site, but it does not protect the wearer during a fall or when faced with a rotational injury (
Figure 1).
Figure 1. Industrial safety helmets have a suspension design that prevents injury from vertical impact. These helmets are not designed to prevent injury from side or rotational impacts that would increase injury severity and diffuse axonal injury.
Finite element analysis is a numerical analysis technique utilized to assess the engineering and design of helmets by mathematically modeling physical contributions such as force. This mathematical modeling utilizes a scoring system such as the head injury criteria (HIC) score, incorporating acceleration and time, where a score of 1000 is considered a safe limit
[30]. This widely used score has been utilized to improve and test different helmet materials such as Carbon Fiber and Polyethylene
[31]. In addition, finite element analysis can be utilized to assess diffuse axonal injury computationally via von Mises stress
[27]. A study evaluating simulation-based impact on construction helmets indicated that a 2 kg cylinder vertical impact has a 50% chance of causing mild diffuse axonal injury, which increases in severity as impact speed increases. However, it was limited by the lack of modeling any elements of rotational acceleration
[27]. This testing provides classifications for helmets for one-time impact, yet industrial helmets regularly endure multiple impacts. One study evaluated the damage and vulnerability induced by repeated impacts on the helmets’ shock absorption performance
[32]. An endurance limit was determined for the helmet, where cumulative damage from multiple impacts degraded the shock absorption performance when the impacts were greater than the endurance limit. For example, a type I industrial helmet’s endurance limit was found to be a drop height of 1.22 m
[32].
The largest challenge with construction-related safety is workers wearing the industrial safety helmet. Industrial safety helmets have been accused of being too heavy and uncomfortable to wear while working; thus, many workers often choose not to wear helmets when possible. One initiative for promoting wearing helmets on construction sites has been artificial intelligence technology for safety helmet recognition
[33]. While improvements in industrial helmet design are needed for comfort and protection against rotational injury, the use of these safety helmets is still effective in protecting the wearer from injury. An analysis of work-related injuries demonstrated that safety helmets meeting current OSHA and ANSI requirements more effectively prevented intracranial injury in comparison to no helmet at all
[34].
While helmets can effectively dissipate and reduce impact and acceleration-deceleration forces, they do not entirely prevent energy transfer and the risk of concussion. The pathophysiological consequences of single or repeated concussions while wearing a helmet are needed but present challenges when adapting experiments to translational TBI models. Helmets are designed for human heads and impact based on bipedal kinematics, where common TBI animal models introduce varied head and brain shapes and quadrupedal movement that can change the fundamental dynamics of applied forces, where the temporal and spatial profile of physiological alterations, diffuse axonal injury, and secondary injury sequelae can be influenced.
In conclusion, industrial safety helmets are beneficial for preventing head injury, but there is a large gap in work-related injury research. Mechanistic understanding and appropriate injury models, including rotational acceleration, are required to develop more protective helmets for work-related traumatic brain injuries.
4. Secondary Injury Prevention
While there are likely a plethora of factors that influence TBI, linear and rotational acceleration are two of the most significant. Linear acceleration is believed to produce focal trauma at both coup and contrecoup locations within the brain
[35]. Examples of focal injuries include epidural hematomas, skull fractures, and cerebral contusions
[35][36]. Conversely, rotational acceleration produces more diffuse trauma within the brain through shearing forces
[35][37]. For years, reducing linear acceleration has been one of the primary goals of helmet design. However, it was not until 2018 that the National Operating Committee for Standards in Athletic Equipment updated the criteria to include rotational acceleration in the design of new helmets
[38]. In a 2020 evaluation of combat helmets released by the US Army Combat Capabilities Development Command, they demonstrated that while, on average, the Army Advanced Combat Helmet (ACH) produced a statistically significant reduction in linear acceleration compared to no helmet. However, it failed to produce a statistically significant average reduction in rotational acceleration and even increased rotational acceleration at higher force impacts
[39]. Consequently, helmet designs in sports and combat have historically neglected to consider rotational acceleration and the resultant more mild traumatic brain injuries (mTBI) such as concussion and subconcusion
[8][40].
Rotational acceleration produces axonal shearing, obstructing axonal function, and causing an accumulation of amyloid-beta precursor protein that peaks after 24–48 h
[41][42][43]. In addition, shearing and mechanical forces produce plasma membrane instability resulting in potassium leakage and neuronal depolarization
[44][45]. As a result, the excitatory neurotransmitter glutamate is released and binds NMDA receptors, generating a cycle of potentially neurotoxic hyperexcitation
[43][46][47][48]. This drastically elevates intercellular calcium and sodium concentrations and destabilizes mitochondrial function as a vital calcium buffer system within the cell
[49][50][51]. As a result, calcium-dependent proteases and lipases are activated and reactive oxygen species production increases, causing oxidative stress within the cell
[52][53]. Elevated oxidative stress within the cell is believed to promote perturbation within the endoplasmic reticulum (ER) and a subsequent accumulation of unfolded proteins. The unfolded protein response (UPR) initially functions to resolve ER stress through inhibition of protein synthesis and proteolysis of misfolded or unfolded proteins
[54][55]. With a failure of ER stress resolution over time, the ER UPR pathway ultimately upregulates caspases and pro-apoptotic pathways, promoting cell death
[54][56][57][58]. These functions can be exacerbated with repeated injury, and may be targeted for helmet innovation.