Schutt Sports
DNA Football Helmet

Issue presented to the SKYDEX Team
Schutt Sports, the world's largest provider of football helmets and faceguards wanted to improve the overall performance or their protective sports equipment with a new product line, the DNA. Current protective padding in football helmets hadn't changed significantly in the past 30 years. Schutt asked SKYDEX to create a padding product for the helmet that would meet all standards for impact protection and superior comfort.

Specific goal for the final product
Schutt tasked the SKYDEX application engineers to provide a helmet with impact protection that was consistent with current industry standards. In addition, the new style and branding had to be significantly more comfortable, easily maintained and resistant to mildew and degradation in harsh environments.

Research and Design Process
In order to provide the best protection and comfort, the SKYDEX shock absorbing liner was designed to be thinner than traditional impact absorbing materials, leaving extra room for a comfort liner. The extra space SKYDEX created was used to implement a state-of-the-art air bladder which produced a dramatic improvement in comfort.

Design parameters were determined by testing existing products. Several prototype SKYDEX molds were used to assess form and function. Final tuning was done using several different plastic resin grades and raw material consistent with the tenability of patented SKYDEX technology. Several hemisphere ellipse ratios were engineered and tested. During the final design process, a manufacturing plan was concurrently designed to provide high volume production using the twin sheet thermoforming process.

Final outcome of the R & D process
The Schutt DNA Football helmet featuring SKYDEX technology meets the standards set forth by the National Operating Committee on Standards for Athletic Equipment (NOCSAE). The product launched in 2003 and was chosen as a finalist for the 2004 SGMA International Sports Product of the Year Award.

Schutt Sports has experienced record sales and has launched a product line extension, incorporating SKYDEX technology into a DNA batting helmet. The SKYDEX designs have opened the door for several other application.