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In this paper, the design methodology of composite ballistic helmets has been enhanced considering biomechanical requirements by means of finite element analysis. Modern combat helmets lead to a new type of non-penetrating injury, the Behind Helmet Blunt Trauma (BHBT), generated by the deformation of the inner face of the helmet, the so-called backface deformation (BFD). Current standard testing methodologies use BFD as the main measure in ballistic testing. Nonetheless, this work discusses the relationship between this mechanical parameter and the head trauma (BHBT) by studying different head injury criteria. A numerical model consisting of a helmet and a human head is developed and validated with experimental data from literature. The consequences of non-penetrating high-speed ballistic impacts upon the human head protected by an aramid combat helmet are analysed, concluding that the existing testing methodologies fail to predict many types of head injuries. The influence of other parameters like bullet velocity or head dimensions is analysed. Usually, a single-sized helmet shell is manufactured and the different sizes are adjusted by varying the foam pad thickness. However, one of the conclusions of this work is that pad thickness is critical to avoid BHBT and must be considered in the design process.

Many discrepancies are found in the literature regarding the damage and constitutive models for head tissues as well as the values of the constants involved in the constitutive equations. Their proper definition is required for consistent numerical model performance when predicting human head behaviour, and hence skull fracture and brain damage. The objective of this research is to perform a critical review of constitutive models and damage indicators describing human head tissue response under impact loading. A 3D finite element human head model has been generated by using computed tomography images, which has been validated through the comparison to experimental data in the literature. The threshold values of the skull and the scalp that lead to fracture have been analysed. We conclude that (1) compact bone properties are critical in skull fracture, (2) the elastic constants of the cerebrospinal fluid affect the intracranial pressure distribution, and (3) the consideration of brain tissue as a nearly incompressible solid with a high (but not complete) water content offers pressure responses consistent with the experimental data.

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