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Ballistic helmet: Why ceramics from Schunk save lives

In tactical operations, special operations, or urban crisis situations, one thing is clear: the human head remains one of the most vulnerable targets. That is why ballistic helmets are an indispensable part of modern protective equipment. They offer protection against bullets, shrapnel, and blunt force—and must be lightweight, stable, and reliable.

However, what is often overlooked is that the actual protective mechanism of these helmets is not in the outer shell, but inside – in an invisible layer of technical ceramics. This is exactly where Schunk comes in.

We supply the crucial ceramic components on which many high-performance helmets worldwide are based. Materials such as SafeGuard GD and SafeGuard B4C protect thanks to their exceptional hardness, low weight, and ability to fragment even armor-piercing projectiles and absorb the impact energy.

Thanks to innovative processes such as 3D printing with IntrinSiC®, even complex helmet structures can now be produced – precisely fitting, lightweight, and highly effective.

So anyone who thinks that protection is just a matter of the shell has not looked at the core: that is where safety begins – with high-performance ceramics from Schunk.

Ballistic Helmet Overview

What is a ballistic helmet? – Structure, effect, protection classes

A ballistic helmet is much more than just head protection. It is a complex safety system designed to protect the wearer from firearms, shrapnel, impacts, and explosive forces. Originally reserved for military units, ballistic helmets are now standard equipment for special police units, private security services, and special forces worldwide.

Structure and function

A modern helmet consists of several layers and components:

  • Outer shell: Usually made of aramid fibers or polyethylene – lightweight and stable
  • Hard ballistic core: This is where ceramic inserts come into play, e.g., plates made of RBSiC or B4C
  • Inner lining & cushioning: For energy absorption, comfort, and stabilization
  • Modular attachments: Mounting rails for night vision devices, communication equipment, visors
     

The ceramic component plays a key role here: it is responsible for fragmenting incoming projectiles and reducing the impact energy before it is transmitted to the head.

Protection classes and standards

Ballistic helmets are classified according to international standards:

  • NIJ (USA): Level IIA to IIIA
  • VPAM: Classification according to protective effect against different calibers
  • STANAG (NATO): Particularly relevant for military applications
     
Ballistic helmet, ballistic seat shell as well as SK4 protection plate made of technical ceramics

Requirements for modern helmets:

 

  • Minimum weight with maximum protection
  • Resistance to multiple hits (multi-hit)
  • Modularity (e.g. for add-on parts)
  • Wearing comfort and ergonomics
  • Stability at extreme temperatures and humidity
     

Today, a ballistic helmet is a high-tech product – and the ceramic used determines its protective potential.

Ceramic Protection in Helmets

Hard ceramic ballistics in helmets – invisible but indispensable

While outer materials such as aramid or polyethylene are clearly visible in ballistic helmets, the crucial protective material remains hidden: ceramic hard ballistics. This thin, extremely hard layer inside the helmet is responsible for ensuring that projectiles are destroyed rather than penetrating the helmet – often in a fraction of a second.
 

How ceramic components work

Upon impact, a projectile hits the ceramic plate. Thanks to its high hardness, it immediately fragments the projectile. The resulting fragments are stopped by the subsequent layers (e.g., fibers, damping material). The major advantage is that the kinetic energy is absorbed before penetration and distributed over a larger area, drastically reducing the risk of serious head injuries.
 

Ceramics vs. alternative materials

Compared to traditional metals such as titanium or pure plastic solutions (PE), technical ceramics offer significant advantages:

  • Greater hardness than metal alloys
  • Lower weight than aluminum oxide plates
  • No deformation under heat or multiple impacts
  • No corrosion, even under extreme conditions

Advantages of ceramic materials in helmets:

 

  • Extremely high hardness values (up to 29,000 MPa)
  • Low density, ideal for mobile emergency services
  • Splinter protection in case of multiple impacts
  • Temperature and corrosion resistant
  • 3D moldable for modern helmet geometries (e.g., FAST, MICH)

 

Why Schunk?

Schunk's materials for ballistic helmet applications

Schunk supplies the critical ceramic materials that make their protective effect possible. With one of the world's broadest portfolios of high-performance ceramics for ballistics, the company offers everything manufacturers need to produce state-of-the-art helmets – from series solutions to customized high-end components.

Ceramic Materials for Helmets

Three Materials – Maximum Protection

 Material microstructure of the technical properties and surface structure of CarSIK-G & CarSIK-Z.

SafeGuard GD: Robust standard solution for series helmets

 

  • Reaction-bonded silicon carbide (RBSiC)
  • Density: 3.10 g/cm³
  • Hardness: 25,000 MPa
  • Ideal for series helmets, e.g., police, military
Material microstructure of the technical properties and surface structure of CarSIK-B4C

SafeGuard B4C: When weight is crucial

 

  • Reaction bonded boron carbide (RBB4C)
  • Density: only 2.85 g/cm³
  • Hardness: up to 29,000 MPa
  • For elite units with the highest mobility requirements
Material microstructure of the technical properties and surface structure of IntrinSiC

IntrinSiC® & IntrinSiC® B4C: Tailor-made protection through 3D printing

 

  • CAD-based manufacturing without molds
  • Curves and recesses for NVG or visors possible
  • Ideal for special helmets with complex geometries

Comparison table of ceramic materials for helmets

SafeGuard GD
  • Type: RBSiC

  • Density: 3,10 g/cm³

  • Hardness: 25.000 MPa (Vickers)

  • Special features:

    • Robust standard material

    • Ideal for helmets in serial production

SafeGuard B4C
  • Type: RBB4C

  • Density: 2,85 g/cm³

  • Hardness: 29.000 MPa (Vickers)

  • Special features:

    • Extremely lightweight

    • Maximum protection

IntrinSiC®
  • Type: RBSiC (3D)

  • Density: 3,05 g/cm³

  • Hardness: 25.000 MPa (Vickers)

  • Special features:

    • Design freedom through 3D-printing

    • for complex helmet shapes possible

IntrinSiC® B4C
  • Type: RBB4C (3D)

  • Density: 2,88 g/cm³

  • Hardness: 29.000 MPa (Vickers)

  • Special features:

    • Lightweight

    • Customization via 3D-printing

Diverse Application Scenarios

Areas of application & scenarios for ceramic helmet protection

Military use

  • Combat helmets for infantry & special forces
  • Integration into modular protection systems (visor, NVG, communication)
     

Police & security services

  • Protection in terrorist and hostage situations
  • Ballistic head protection for SWAT and other tactical police units
     

Civil defense & security services

  • Crisis intervention, bomb disposal
  • Personal protection in high-risk areas

Ceramic helmet deployment scenarios:

 

  • Infantry combat
  • Anti-terrorism operations
  • Explosive device effects (IED)
  • Urban house-to-house combat with multiple threats
  • Modular expandable helmets for long missions
Ceramic Protection of the Future

Schunk Ceramics for Advanced Helmets

Ballistic helmets today are much more than simple protective shells – they are high-tech systems in which every gram, every shape and every material counts. At the heart of this development is technical ceramics.

As one of the leading suppliers of high-performance ceramic materials, Schunk provides the invisible but crucial component that gives modern helmets their protective effect. Whether with the proven SafeGuard GD, the ultra-light SafeGuard B4C or the innovative 3D-printed IntrinSiC® solutions – ceramics from Schunk mean state-of-the-art protection.

Ceramic protection starts on the inside – where it counts. And Schunk ensures that this protection delivers what it promises.