Enhancing Helmet Protection: The Evolution of Up-Armor Solutions
The quest to increase helmet protection has been a constant in human history—an arms race spanning centuries. From deflecting edged weapons and arrows to stopping fragmentation and bullets, innovators have always sought the next breakthrough to safeguard our heads. In this article, we’ll explore the evolution of up-armor (or applique) solutions, from historical designs to cutting-edge modern advancements, including our own lightweight rifle-rated up-armor at Hard Head Veterans. Plus, stick around for an exclusive video where we put our latest solution to the test!
A Historical Perspective: The German M17 Helmet Upgrade
During World War I, Germany pioneered one of the earliest up-armor solutions for their M17 helmet. This applique consisted of a front plate attached via ventilation lugs and a leather strap around the back. Designed for trench warfare—where the head was often the first target exposed—this upgrade offered enhanced protection against shrapnel and small arms fire. Today, these historical pieces are collector’s items, still available for purchase here, though they come with a hefty price tag.
Modern Up-Armor Innovations: Stronger Materials, Same Concept
Fast forward to today, and while the materials have evolved, the core idea of adding protective appliques remains unchanged. Companies like Velocity Systems have developed solutions like the SLAAP plate, designed for high-cut helmets. This plate boosts ballistic protection, stopping rounds like the 7.62x39mm, 123-grain FMJ with mild steel core at 2,400 FPS, all while keeping backface deformation (BFD) under 25.4mm (1 inch). Curious about its origins? Check out these photos.
Photo From http://soldiersystems.net/2012/09/27/ach-slaap-velocity-systems/
Our Early Experiments: Next-Generation Metals
At Hard Head Veterans, we’ve explored our own up-armor concepts in collaboration with Revolution Armor. Using next-generation metals, we engineered solutions capable of defeating 7.62x51mm, 7.62x39mm, and 5.56x45mm at full rifle velocities with minimal BFD. However, these designs came with challenges:
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Weight: Metal-based up-armor is significantly heavier than ceramic or fiber alternatives.
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Formability: The extreme hardness of these metals makes them difficult to shape into helmet-compatible curves without compromising ballistic integrity.
While effective, these solutions are best suited for static applications—like a gun turret—or short-term mobile use. But we didn’t stop there.
After extensive R&D with Adept Armor Systems, we’re thrilled to introduce our latest up-armor solution for the ATE line of ballistic helmets. Weighing just 1 pound, this applique is crafted from a silicon carbide, delivering exceptional protection in a thin, lightweight package. Here’s how it performs:
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7.62x39mm M43 LS, 123.7-grain MSC at 2,410 ft/s: No penetration, 21.206mm BFD.
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5.56x45mm M855, 62-grain at 3,156 ft/s: No penetration, 14.306mm BFD.
Ready to upgrade your helmet? You can find it here.
Video Spotlight: Testing Our Up-Armor
Wondering how this up-armor holds up under fire? Here's a video where we test our rifle-rated applique against common rifle rounds. Watch as we demonstrate its stopping power, lightweight design, and real-world performance
Common Questions on Up-Armor and Head Protection
A frequent question we hear is: “Even if the helmet stops the round, won’t the impact turn you into a vegetable or snap your neck?” The short answer: No. As long as backface deformation stays within acceptable limits (like our sub-25.4mm results), the worst-case scenario is a mild concussion. And your neck? It’s far stronger than you think—rifle recoil doesn’t rip your shoulder off, right? Modern ballistic helmets are engineered to mitigate these threats effectively. For a deeper dive, check out our detailed blog here.
Another question you may be asking, is what about the face? As with everything in helmet armor solutions, there seem to be trade-offs and with face protection, it's no different. You have to trade off the cost of weight and vision, for protection and coverage. On the market currently, there are a number of options that address this issue. From the common face shield, you see riot police wearing that may offer blunt to ballistic protection. To full mandibles and cheek protection like you would see on helmets of ancient times. 3M captured the most recent U.S. Army ballistic helmet award for their IHPS helmet that provides all of these things.
The Future of Helmet Protection
As technology advances, so will up-armor solutions. Lighter materials, smarter designs, and even sci-fi-inspired concepts—like Star Trek-style force shields—could one day redefine head protection. Until then, innovations like ours at Hard Head Veterans are pushing the boundaries of what’s possible.
From WWI steel plates to our silicon carbide applique, the evolution of up-armor reflects a relentless drive to protect. Ready to enhance your gear? Explore our rifle-rated up-armor here and stay tuned. This technology is always improving.