Abstract: A new process for making headgear. The process comprises the step of insert molding an armature into helmet segments to produce a protective helmet having superior characteristics. The process also comprises the step of strategically locating a retention system on the helmet to provide increased stabilization of the helmet on the wearer's head. The process further comprises the step of attaching an improved strap guide to the helmet. One embodiment of this invention is a process for making an insert-molded helmet that can be converted into a pouch. Another embodiment of this invention is a process for making a helmet that includes a protrusion at the back of a helmet suitable for a compartment.