Combat helmets have been used and created since the dawn of recorded history, when our forefathers recognized the importance of head protection. The development of armor was affected by two factors: the time it was created and what the army required. A soldier’s value, no matter when or where, rested on their equipment, particularly the helmet, which was both vital and expensive. The buhurt helmets evolved with the weaponry it was intended to fight against, demonstrating how defense tools evolved throughout time.
So, helmets were first recorded approximately 3000 BC. They were made from strong crocodile hide. This material was easy to shape, resulting in the finished product.
From the Great Helm to the Hounskull
The transition from the big helm to the hounskull is a symbol of the protective capabilities and wearer ergonomics that have undergone centuries of improvements. Great helms reached their peak during the 13th and early 14th centuries and their construction featured huge, thick steel plates that surrounded the whole head and face, with several such plates being often welded together into one heavily fortified structure. Although very effective in the case of glancing hits, the whole helmet design drastically limited the areas of the head that could see and move, the ventilation, and the rotation needed for the cervical vertebrae.
First seen in the late 14th and 15th centuries, the hounskull or the helmet with a shape that is more tapered and curved, that distributes the weight of the helmet uniformly across the whole cranium and reduces the wearer’s tiredness during long fights, was gradually replacing the heavy large helmets. Armorers studying these former styles resort to finite element modeling (FEM) to forecast the impact forces and locate the points of stress concentration, keeping the overlaps but dispersing the energy more and lessening the distortion.
Modern design considers the movement of the head and neck. Each of these helmets is a unit with the head of the wearer, so it is torqueless during lateral impacts. The adjustable inners and modular shields are meant to deliver a live optimal field of vision, breathing corridors, and compatibility with armor for the shoulders and neck.
How Safety Standards Shape Modern Buhurt Helmets
Today’s buhurt helmets are crafted with strict HMB and IMCF safety regulations in mind regarding thickness of materials used, sizes of internal gaps, structural strengthening, and impact absorbing. The main materials for helmets, 2-3 mm tempered high-carbon or spring steels, are subjected to heat treatment for attaining all three properties—tensile strength, ductility, and hardness—so that they can endure over 100 J high-energy impacts with no shattering or permanent deformation occurring. Once helmets are finished, their faceplate and visor are designed within strict protocols where openings are made that will not let competition weapons penetrate through, but still give fairly unobstructed view.
Concussion-proofing through cushioning material is as critical as actual steel. Helmets contain different kinds of foam along with viscoelastic inserts layered in such a way that they absorb kinetic energy and lessen the stresses on the skull and the spinal cord. Modular straps, replaceable liners, and chin harnesses keep the helmet steady during movements, thus reducing the probability of shifting during grapples or strikes. The edge finishing, the position of rivets, and the welding of parts all pass through a very careful evaluation to ensure that there are no weak points that might fail under repeated stress. Modern buhurt helmets undergo corresponding impact testing to match safety standards by felling tests, pendulum impact, and repetitive loads testing are just some of the ways through which this is done.
Inside the Workshop: The Making of a Helmet
Medieval Extreme states the manufacturing period for the parts and armor the customers can buy and it can be as high as one and a half years. How is it done?
- The measurements are taken on the gambeson or bare head and a computer-aided design (CAD) model is made to approximate fit, stress points, and articulation, then the customer is asked for permission to begin forging.
- High-carbon or spring steel is cut, then it goes through cold- and hot-forming, heat treatment, and shaping. Plates, visors, neck guards are attached with sliding rivets and internal cushioning to ensure proper movement and stability.
- Helmets undergo impact and cyclic load testing to guarantee compliance with HMB/IMCF which is then followed by polishing, edge finishing, rust protection, and optional engraving or gilding.
- All the processes of custom fitting, material preparation, forging, iterative changes, and safety testing add up to the 12- to 18-month lead time.
The flat-faced bascinet dome is composed of steel 30HGSA, having a reinforced 2.5 mm crown and 2 mm lower walls that are thick where it matters most. The fitted padded liner adds to the comfort one has during a fight while the wool aventail, which is reinforced with three tough steel plates, ensures that the neck is very well protected in case of a surprise attack. The visor is secured with a button and strap system and it also comes with optional mounting holes that provide extra stability during intense fighting.
Choosing the Right Helmet for You
A perfect buhurt helmet balances between three characteristics: fit, protection, and movement, that is to say, if it protects you and fits well, you can move easily and still not be limited by the helmet. Assess the weight, visor design, neck protection, and padding components to select the style that works best with your combat needs. The lighter helmets like the bascinet give speed, while the Italian Barbute offers more covered area and sturdiness. Excellent fitting is crucial for both safeguarding and performance.
Step into the Medieval Extreme workshop and check out our battle-ready helmets, made by artisans for maximum comfort, protection, and historical authenticity. Schedule your consultation now.
