Football aficionados and safety advocates alike have reason to celebrate, as LIGHT Helmets, a California-based sports equipment manufacturer, has achieved a major breakthrough with its new Apache helmet line. Created under the guidance of Kodiak Brush, an MIT alumnus and former middle linebacker, the Apache has been acknowledged by Virginia Tech’s respected helmet-testing lab as the highest-performing helmet in terms of safety they have ever tested, according to a statement obtained by MIT News.
Brush's focus on innovation has led to a helmet design that's not only lighter but also safer. In a mechanical engineering twist, the former collegiate athlete managed to weave his understanding of football dynamics with advanced technology to reduce the helmet's weight and, consequently, the energy impact of each collision. "We’re trying to lower the overall amount of energy going into each impact, by lowering the weight of the helmet," Brush said in an MIT News interview, highlighting the intricate balance required in the design process.
The initiative is a personal one for Brush, who, as a player, was well aware of the risks and incidences of concussions inherent in the sport. He remarked on the challenges of diagnosing concussions during gameplay and the conflict athletes often face in choosing between their health and their desire to continue playing. Though no helmet can guarantee absolute protection, enhanced safety measures can make significant differences. Brush's firsthand experience on the field has thus informed his mission in the lab. After graduation, he utilized his engineering know-how as an accident reconstruction expert before shifting to product design, which led him back to the world of football protection.
In developing the Apache, Brush took apart competitor helmets to understand their composition and limitations. This approach, reminiscent of his time at MIT's product engineering process class, resulted in a helmet utilizing an impact-modified nylon shell and a 3D-printed thermoplastic polyurethane liner. Such materials allow the helmet to compress considerably more under pressure, thereby extending the impact duration and reducing its severity. "The idea with the flexible shell is we’re now able to squish both the inside and outside of the helmet, which lets you extend the length of the impact, and lower the severity of the hit," Brush explained in his interview with MIT News.
The impressive performance of the Apache helmet is causing a surge in industry excitement and consumer demand. LIGHT Helmets, despite smaller research and development resources, has managed to pose a challenge to its larger competitors, aiming for tenfold growth in sales this year. Their innovative product is testament to the potential of combining academic know-how and real-world application. As more helmets from LIGHT make their way into the NFL—the majority of teams are already using the company's products—Brush's contribution serves as both a technological triumph and a beacon for player safety.
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