New 3D Printed Helmet Suspension System for Military and Law Enforcement

When most people think of making helmets safer, 3D printing technology is probably not the first thing that comes to mind. However, over the years we have seen numerous examples where additive manufacturing has contributed to better-fitting, more comfortable helmets, including in the NFL, NHL and bike riding. Now, we have another to add to our list. ArmorSource has launched a new 3D printed helmet suspension system, named AireSupport Max, that has been designed specifically for the military and law enforcement.

This actually is not a new idea. Back in 2021, the US Army awarded General Lattice a contract to improve helmet impact absorption by replacing the traditional foam with 3D printed lattice structures. However, to our knowledge, this is one of the first times we have seen a military equipment provider and not a 3D printing company behind the initiative. ArmorSource, founded in 2005, is one of the world’s leading manufacturers of ballistic helmet solutions. The company’s mission is to enhance ballistic capabilities while maintain comfort and durability. And now it seems that 3D printing is helping in that mission.

A closer look at the 3D printed helmet suspension system, including the lattice pads

A 3D Printed Helmet Suspension System for Superior Performance

So what do we know about this 3D printed helmet suspension system? Well, similar to other helmet projects, AireSupport Max uses lattice designs, known for their energy absorption, among other benefits. These are 3D printed, and although the process was not specified, other 3D printed lattice helmets have used vat photopolymerization processes. This is likely the case for this helmet suspension system as well.

Nick Gramly, the VP of Technology for ArmorSource, further explains, “What sets AireSupport Max apart is its innovative design, crafted from a printed polymer structure. The unique 3D structure ensures superior airflow and ventilation. This construction not only maximizes breathability but also delivers exceptional comfort, blunt impact protection, and stability-key features that will set the bar for what premium head protection should feel like.”

The company notes that key highlights of AireSupport Max are numerous. These include superior comfort as the 3D printed helmet suspension system is able to adapt to the wearer’s head shape, but also the fact that it exceeds U.S. Army Blunt Impact requirements, has zero water absorption and is durable. Not to mention, thanks to 3D printing and the lattice design, it is lighter, maintaining a minimal weight while remaining strong and resilient. It is for this reason that ArmorSource considers that the helmet suspension could redefine the standard for high-performance head protection.

The 3D printed lattice structures within the AireSupport Max

Already, the AireSupport Max has been tested in real-world scenarios with a select group of operators who described it as “a game-changer in the industry.” The company further notes that it will offer “unmatched head protection” for the military, law enforcement and tactical professionals. You can learn more on ArmorSource’s website HERE.

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*All Photo Credits: ArmorSource