How Is a Kevlar Helmet Made?

Updated March 16, 2017

Kevlar helmets are used by more than just soldiers. Kevlar is used in motorcycle helmets and police officer headgear as well. The process of manufacturing a Kevlar helmet consists of layering strips of Kevlar over a lightweight frame.

History of the Kevlar Helmet

The Kevlar helmet was first used by the United States military in 1976 during the Vietnam War. The development team that created the Kevlar helmet initially wanted to make it lighter than the steel helmet used by soldiers in previous wars. When the helmets were finished they ended up having the same weight, but offered greater protection and balance.


The lightweight material that forms the foundation of a Kevlar helmet is usually a synthetic ballistic material. Layer upon layer is then grafted to this foundation until the helmet is sufficiently durable to protect the wearer from cranial damage from shrapnel, bullets or other heavy impact.

Benefits of Kevalr

The primary advantage of Kevlar is that it is lighter and more flexible than steel. It offers high tensile strength and is also considerably more flexible.

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About the Author

Mike Thurau has written for his college newspaper since 2009. He has written editorials and freelance articles for the "BG News" and Cleveland's "Plain Dealer." He is currently enrolled in Bowling Green State University studying political economy.