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HeadSaver Testing

Impact Testing of HeadSaver soft protective helmets by Melbourne Testing Services.

Report No: MT-11/516




Impact Testing

Test Synopsis

A protective soft helmet designed to reduce the magnitude of impact forces from accidental head collisions was delivered to the MTS laboratory for testing.


As advised by the client, the soft helmet is to be worn mainly by elderly people to provide extra head protection in the event of head collisions. The cushion is manufactured from a polyester and spandex foam composite and incorporates an adjustable rear section and chin strap for a comfortable fit. Upon arrival at the laboratory, the test item was examined and the following details recorded:


HeadSaver Soft Helmet

  • Height: 110mm

  • Breadth 150mm

  • Length 210mm

  • Wall Thickness (nom.): 12mm


At the request of the client, impact tests were to be conducted on HeadSaver Soft Helmet to determine the impact force reduction attributes.

Test Procedure

A specially designed test rig was constructed to conduct impact drop tests at pre-determined drop heights. Three impact orientations namely frontal, lateral and posterior impacts were conducted.The support frame was rigidly bolted to the laboratory test floor and the test sample was fitted as shown. An accelerometer, mounted on a flat faced striker with a mass of 2.3kg, was released at a distance of 0.04m, 0.08m, 0.12m, 0.16m and 0.20m with respect to the contact surface. The striker mass was fitted with roller bearings, which allowed a smooth descent with minimal friction. A high speed data acquisition system was then used to record the impact forces autographically for the respective drop heights.


Note: A fibreglass head mannequin (3mm thickness) was used to provide support to the soft helmet during testing

Test Data

Test data curves for HeadSaver soft helmet at a drop height of 0.04m, 0.08m, 0.12m, 0.16m and 0.20m equivalent to impact energies of 0.92J, 1.84J, 2.76J, 3.68J and 4.6J are provided.

Based on the recorded peak impact forces (for impact tests conducted with and without the HeadSaver soft helmet) and the corresponding impact energies, the energy absorbed (in per cent) vs impact energy for the posterior impact tests were calculated and are also provided.

Posterior Impact Tests

Posterior impact tests conducted for the HeadSaver soft helmet also resulted in a fifty per cent (50%) reduction in the peak force at a drop height of 0.12m

Frontal Impact Test

At a drop height of 0.12m, the peak impact force (g) recorded without the HeadSaver soft helmet was observed to be 10g. On the other hand, a peak impact force of 4.7g was recorded with the HeadSaver soft helmet. Therefore, this represents a 53% reduction in the peak impact force.

Lateral Impact Tests

For a similar drop height of 0.12m, a 56% reduction in the peak impact force was observed for the tested sample.

Test Observations

As shown,the peak impact forces were observed to be fairly uniform across the different impact orientations for the tested sample. 


For the range of impact tests described and conducted herein, lower peak impact forces were observed with the HeadSaver soft helmet when compared to impact tests conducted without the HeadSaver soft helmet


While HeadSaver can achieve excellent and impressive results, no product can claim to be 100% effective all of the time. HeadSaver is not guaranteed to work in every individual instance. HeadSaver is not suitable to be used as a head protector either in an industrial or construction environment nor for sporting activities. The HeadSaver is not designed to protect the head from falling objects. Therefore, HealthSaver Pty Ltd and HeadSaver make no implied or express guarantee that their products will prevent injury.

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