Prior to 1970, no standards existed in the making of football helmets, and there was an average of two head injury fatalities for every 100,000 players. To reduce head injuries, manufacturers have made voluntary changes to the way they design and build football helmets. Changing the exterior size of the helmet has led to incorporating softer, more impact-resistant interior padding materials, and the safety results have been noticeable: 1990 was the first year since 1931 that no football head injury fatalities occurred, according to the National Operating Committee on Standards for Athletic Equipment.
Football Helmet Standards
The National Operating Committee on Standards for Athletic Equipment designs tests and provides manufacturing standards to sporting goods companies. The NOCSAE works with manufactures to develop and implement football helmet safety features, particularly the padding inside the helmet to protect the player. Each manufacturer designs and builds its own padding for helmets and padding is not interchangeable with other helmets.
Overall Construction
The exterior shell of a football helmet is constructed of polycarbonate plastic, molded to encase several layers and types of dense foams and air bladders. Polycarbonate is a tough, stable thermoplastic able to withstand repeated blows without damage. Youth helmets often are manufactured with acrylonitrile butadiene styrene, the same ABS plastic from which safety helmets are manufactured.
Vinyl Nitrile Foam
The stiff foam used in the crown of some football helmets is constructed of vinyl nitrile foam. The dense, lightweight foam withstands impacts with little to no damage. Used as protection in a variety of activities and extreme sports, it is durable and resistant to extreme temperatures. Some youth helmets use the vinyl nitrile foam inside the helmet and cover it with a vinyl-covered soft foam liner.
Air Bladders
Molded, one-piece bladders designed to fit inside the helmet help with the fit and comfort of the helmet. The bladder is filled with air once the helmet is on the player's head and provides an additional layer between the head and the shell of the helmet. Upon impact, the air bladder helps to absorb some of the shock and disperses it to lessen any potential damage.
Thermoplastic Urethane Foam
Thermoplastic urethane combines the characteristics of rubber and thermoplastic into one material. Some manufactures use this product in lieu of traditional foam padding inside the helmet. The material doesn't break down over time in the way traditional foam does, so is able to withstand impact after impact while maintaining its shape and comfort for the wearer. This often is found in more expensive football helmets.
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