Some rifle‑rated helmets save lives (others just pass tests): why all rifle-rated helmets are not created equal

It’s important to recognize that ballistic helmets, especially those marketed as “rifle-rated” are not created equal.

Rifle-rated helmets are the newest generation of ballistic combat helmets. Traditional combat helmets are designed to protect against fragmentation and handgun threats – commonly referred to as Level IIIA-type or HG2-type handgun threats. This means a helmet with a IIIA rating is designed to stop pistol rounds up to and including a .44 mag, 9mm, or 357 Sig.

As the threat environment has evolved, the proliferation of intermediate-calibre rifles (7.62×39 mm AK‑pattern rifles, 5.45×39 mm and 5.56×45 mm weapons, mild-steel-core and other common rifle threats) and the rise in close-quarters urban combat, is forcing militaries to recognise that the level IIIA-type threat protection rating no longer provides sufficient protection against the reality of threats that soldiers actually face in the field.

Moving beyond the Level IIIA-type or HG2-type handgun threat protection level has been enabled by a raft of technological advances, including advanced composite materials, no-through hole shells, and improved energy absorbing liners that together improve the protection vs weight balancing act. These ballistic helmets, typically marketed as “rifle-rated” now aim to protect against Level III/RF1-type rifle threats, such as 7.62 FMJ lead core.

The issue is, there is no industry-standard for the methods used to test and qualify these helmets for rifle protection. Some helmets are tested using lower-velocity rifle cartridges, reduced-load ammunition, or cartridges such as .300 Blackout. While these are technically rifle rounds, they operate at significantly lower velocities and energies than common military rifle threats.

This is where Team Wendy differentiates itself. The company’s RIFLETECH rifle-rated ballistic helmet protects against Level III/RF1-type rifle threats, with transparent testing data available so that potential users can understand exactly the threats against which it will provide protection in real-world scenarios.

“By providing detailed calibre testing data, there is no misunderstanding of what we are classifying as a rifle calibre,” Shawn Kneisel, Product Specialist, Team Wendy, said. “RIFLETECH is evaluated for resistance to penetration at muzzle velocity, which is the fastest speed a round leaves the weapon, and is the critical measurement when testing rifle ratings.”

Many manufacturers claim rifle ratings but only test their helmets at lower velocities, often specifying a speed that is less than muzzle velocity.

“This means that while the helmet might stop a round under certain conditions, it requires the shooter to be at a distance where the bullet’s velocity has decreased,” Kneisel said. “In extreme terms, almost any helmet could be called “rifle-rated” if the bullet is slow enough due to distance.”

By rating the RIFLETECH helmet to stop rifle rounds at muzzle velocity, it reflects the realities of close-quarters encounters. This distinction is crucial because real-world altercations occur much closer than the distances required to slow down a bullet.

“The reality of combat today is overwhelmingly weighted toward the urban environment, which compresses engagement distances, making short-range rifle fire exceedingly more common,” Kneisel said. “That means more headshots and higher rates of head injuries.”

RIFLETECH’s tested capabilities include NIJ RF1 (STD 0123.00) and Level III/RF1-type rifle threats (STD 0108.01), tested in accordance with NIJ STD 0106.01; and resistance to penetration at muzzle velocity of 7.62×39 MSC, 7.62×51 FMJ (M80 Ball NATO round), 5.56 M193 BT, and 9mm FMJ RN.

The helmet also has a fragment performance of 17gr FSP V50 ≥ 4430 fps (1350 m/s). V50 testing provides valuable comparative insight into a helmet’s resistance to penetration and its overall material capability.  For reference, an Aramid IIIA helmet has a V50 performance of 650 m/s, while the RIFLETECH helmet that is made from ultra-high molecular weight polyethylene material features a V50 performance of 1350 m/s.  This is > 100% increase in 17 gr. V50 performance and highlights the maximum lifesaving potential of this helmet.

When combined with Team Wendy’s proven Ceradyne® Seamless Shell Technology with no thru holes (ensuring the helmet has no structural weak points), and the RIFLETECH Air Fit helmet liner system – developed through extensive research into traumatic brain injury prevention – RIFLETECH offers industry-leading impact protection in a lightweight, mission-ready design.

“We have engineered and tested RIFLETECH to provide real-world protection where it matters most: at the distances where threats actually occur,” Kneisel said. “Understanding these standards and distinctions can make a critical difference in choosing the right ballistic helmet for your needs.”

Team Wendy