Abstract: A ballistic helmet shell layer in which a plurality of identical fabric segments, each formed with a pointed end and an arcuate end on the locus of a circle having its center at the pointed end, first are laid flat with portions of the edges extending from the pointed ends of adjacent segments butting. After the segments are secured to each other adjacent to the pointed ends, the assembly is formed to a generally hemispherical shape with the remaining side edge portions of adjacent segments coming into butting relationship with only the arcuate edges free.

Abstract: An individually fitted helmet liner includes a plurality of superposed contacting layers, each of which consists of a thermoplastic sheet formed with an array of pockets which are open and unfilled to allow their deformation in response to compressive contact with an adjacent layer. The liner is fitted to an individual wearer's head by heating the sheets to a plastic state, placing the liner between an outer shell and the wearer's head, and pressing down on the outer shell to deform the sheets to the proper extent.