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A Look at the Design Features of a Modern Hard Hat

In 100 years, they haven't changed all that much

By Rain Noe - December 18, 2023

in Tools & Craft

In the 100 years since it's been invented, the design of the hard hat hasn't changed all that much. Edward W. Bullard, the inventor of the original hard hat, would recognize most of the features.

Here we'll look at Klein Tools' 60401 hard hat, a commonly-available model you can pick up at a big box store.

A benefit of using plastic, aside from its light weight, is that you can mold in attachment points. In the 60401, there are slots front and rear that will fit a (Klein) rechargeable headlamp.

Interestingly, Bullard had a model of hard hat that also featured a lighting mount. This one could hold one of the acetylene lights made by his family's company.

The slots on the side of the Klein are for attaching accessories like face shields and hearing protectors.

And where Bullard's design had grommeted holes for ventilation…

Image: The Clark County Museum in Henderson, Nev.

…this modern-day hat features vents. These vents are closeable, via little serrated sliders that are meant to be workable with gloves.

The biggest design improvement to the modern hard hat is the suspension system lined with foam padding, and the ratcheting knob mechanism that fits it to the wearer's head. Bullard's suspension system was leather and undoubtedly fussier to adjust, as well as less comfortable.

The Klein 60401 retails for $55, comparable to the $45 (in today's money) that Bullard's invention cost a century ago.

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Mike Euzent

11 months ago

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The hardhat pictured above isn't really that modern. Further more, a number of large contractors (like the one I work for) won't allow workers to wear traditional hardhats on their job sites. The industry is moving on to construction helmets like the Kask helmet above. The traditional hardhat falls off too easily, often before their head hits the ground. And, if you are lucky enough to have your traditional hardhat (without a chinstrap) on for the first impact the odds are it will have fallen off by your second impact. If you are serious about protecting your head, or being ready to work for a large construction firm skip the old school hardhat and get a helmet

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- Daniel Jordache
  
  Mike Euzent
  
  11 months ago
  
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  I agree with everything you said. Plus these "climber" style hardhats come with a lot of accessories like earmuffs, face shield, visors, goggles and lights that improve usage. Another modern feature is UV exposure tabs that indicate if the hardhat should be replaced.
  
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Peter Wachter

10 months ago

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Using the existing tooling, perhaps modified a bit it should be possible to offer the Klein “brimmed” design with chinstrap capability. Perhaps a Gen2 product. I was a rock climber and can attest to the effectiveness of that helmet design. Like cycling helmets, they stay on all during a mishap.

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