Abstract: A welding helmet having high structual integrity is formed of a single sheet of composite material, such as Kevlar fabric impregnated with a phenolic thermoset resin; a viewing port in the front of the helmet includes a welding lens is either of fixed or automatically darkening type; and curves, bends, folds and steps in the composite material and trim pieces in the viewing port area and about the peripheral rim of the helmet shell provide additional stiffening for the helmet. A method of making a welding helmet of a single sheet of composite material includes pre-forming the composite material to a shape similar to that of the finished molding helmet shape, and placing the pre-shaped composite material in a compression mold and closing the mold to mold the composite material to shape while curing the composite material by applying heat other otherwise assisting in the curing of the composite material; and mounting a welding lens in a viewing port of the welding helmet.

Abstract: A structure formed of a composite material and a support material, the support material being integrally coupled to the composite material by an insert molding process to form an integral structure, and protective head gear, such as a welding helmet, welding shield, hard hat, etc. using such structure. A method for making a structure using sheet-like composite material includes adhering to the composite material a relatively rigid support member or frame by insert molding directly to the composite material.