Numadx has always been committed to advancing safety and performance through innovation, and in 2014, pneumatic cushioning technology reached a critical milestone. The U.S. Army Natick Soldier Research, Development and Engineering Center (NSRDEC) approached Numadx to explore applications for pneumatic cushioning in warfighter helmet protection. What began as an innovation for athletes soon became a game-changing advancement for soldiers facing some of the most challenging and dangerous conditions.
A New Challenge: Protecting Soldiers Against TBIs
By 2014, the increasing prevalence of mild to traumatic brain injuries (TBIs) among soldiers highlighted the urgent need for improved helmet protection. Studies showed that approximately 15-20% of soldiers returning home suffered from some form of TBI. Unlike the impacts encountered in football, warfighters faced complex threats, including blasts, IED under-blasts, ballistic impacts, and shock wave loading—each requiring advanced solutions for head protection.
The stakes were higher than ever. Working alongside engineers from NSRDEC, members of our team worked on a two-year project to develop four pneumatic helmet liner systems tailored to the unique requirements of warfighter safety. Each design was engineered to enhance protection, durability, and comfort under extreme conditions.
Setting a New Standard for Soldier Helmets
Using the same proven methodology as with football helmets, the team benchmarked Advanced Combat Helmet (ACH) systems by replacing their traditional foam liners with pneumatic cushion systems. The results were groundbreaking. Not only did the pneumatic liners outperform existing liner systems in energy absorption and impact performance, but they also revealed a critical advantage: thermal stability.
Unlike traditional foam materials, which stiffen in cold environments and soften in heat, pneumatic cushions maintained consistent performance across extreme conditions. This stability ensured that soldiers operating in diverse environments—from the freezing mountains of Afghanistan to the scorching deserts—received reliable protection. As Natick engineers noted during testing, “We have never seen a liner system perform in this manner.”
At the conclusion of the program, the pneumatic cushion systems set a new benchmark for energy-absorbing design, outperforming state-of-the-art liners in all standardized testing. Complete design engineering packages were finalized, and the technology was readied for integration into the next generation of soldier helmets.
Expanding Applications: Beyond Helmets
The success of pneumatic cushioning in warfighter helmets opened the door to new possibilities. In 2016, the program transitioned from NSRDEC to the Army Research Laboratory (ARL) at Aberdeen Proving Grounds. The focus expanded to explore broader applications for pneumatic cushions, including their physics, material properties, and potential uses in other critical areas of soldier safety.
One significant area of exploration was “under-blast” injuries, which occur when an IED detonates beneath a vehicle. Pneumatic cushions were evaluated for integration into various parts of this scenario, including vehicle seats, flooring, and even soldier footwear. This led to the development of pneumatic boot inserts, designed to sit between a soldier’s sock liner and boot midsole. These inserts aimed to mitigate foot, ankle, and leg injuries caused by blasts, further extending the utility of pneumatic technology.
The Legacy of Pneumatic Cushioning
The advancements made in warfighter protection underscore the versatility and effectiveness of pneumatic cushioning. From helmets that provide superior thermal stability to boot inserts designed to absorb explosive forces, this technology has proven to be a critical asset in protecting those who serve. Pneumatic cushioning has not only outperformed traditional materials but has also redefined the possibilities for safety and performance in high-risk environments.
Numadx is proud to carry forward the legacy of this groundbreaking innovation, applying the same principles of energy absorption and elastic responsiveness to new challenges. Whether it’s on the battlefield or in everyday life, pneumatic cushioning continues to shape the future of protection and performance.
Learn more about the transition from athlete to warfighter protection through the following links:
Fox News – Football Helmets for Soldiers
Military Times – Army Helmet Liner Research
Hattiesburg American – Contract to Improve Army Helmets
