Industrial helmets have followed the same assumptions for decades. Manufacturers produced shells in a few fixed sizes and relied on generic foam systems to take up the slack. Workers accepted the limitations because nothing more precise existed. Loose fits, concentrated pressure and uneven contact translated into discomfort and, in some cases, a higher risk of helmets shifting during an impact. Athletes dealt with similar problems and used improvised padding to reduce localized load, yet the underlying challenge remained unresolved.

BOA works to address these constraints with its patented BOA Fit System, a dial-based performance fit system that aims to stabilize equipment through an uniform, micro-adjustable fit. The company has now begun a collaboration with PPS to deepen its understanding of how headwear interacts with the geometry of the human head. PPS develops tactile sensing technologies that register subtle variations in force across a surface. Its TactileHead platform captures continuous pressure patterns on contoured headforms that replicate anatomical detail, which allows BOA to examine the behaviour of helmet fit systems under conditions that mirror real-world use.

The partnership intends to replace long-standing approximations with quantifiable fit data. Engineers can now observe pressure migration as dial-based micro-adjustments tighten around the circumference of a headform and examine regions that tend to shoulder an excessive load. This process supports the creation of helmet structures that stabilize without producing concentrated points of discomfort. The technology also helps BOA verify helmets across all brands using the BOA Fit System improve fit and performance.

The approach matters for industrial safety because workers depend on helmets that remain stable for extended periods without generating fatigue. Poorly distributed pressure can compromise posture and lead to subtle behavioral adjustments. A comfortable and predictable fit can improve situational awareness and support longer periods of focused activity. Pressure mapping also gives manufacturers a path to reduce the variability associated with traditional size categories and develop designs that accommodate a wider range of head shapes without resorting to bulky padding.

PPS will supply a customized version of its TactileHead system to support research and development work in the BOA Performance Fit Lab. The two organizations intend to document their progress through a technical series that follows the evolution of the headform from initial engineering concepts to prototype validation. Their shared objective centers on producing fit systems that offer reliable stability for workers and athletes who depend on equipment that performs consistently.

Readers who want updates on the collaboration can follow PPS’s Sensor Station newsletter on LinkedIn or explore its website for further examples of tactile sensing applied to wearable products.