Next time you’re viewing football, you may be admiring a significant accomplishment in engineering from a graduate of MIT.
Over the past year, former MIT middle linebacker and mechanical engineer Kodiak Brush ’17 has spearheaded the advancement of football helmets for the California-based sports gear manufacturer LIGHT Helmets. In December, Brush achieved a significant milestone in this endeavor: LIGHT Helmets’ new Apache helmet series was recognized as the highest-performing helmet in safety assessments by Virginia Tech’s prestigious helmet-testing laboratory.
This accolade bolsters LIGHT Helmets’ groundbreaking mission to produce football helmets that are lighter and more secure.
“We aim to reduce the overall energy absorbed during each impact by minimizing the weight of the helmet,” Brush states. “It’s a tricky balance between having a comprehensive, refined product equipped with all the enhancements while simultaneously keeping the helmet’s mass as low as possible.”
No helmet guarantees complete safety, and the NFL conducts its own helmet evaluations, but for Brush, who has played football throughout most of his life, the recent outcomes represented a gratifying achievement.
“It’s truly exciting to be involved in the football helmet industry after playing the sport for so many years,” Brush shares. “We accomplished this with only a fraction of the research and development funding compared to our rivals. It feels amazing to have contributed to something that could benefit so many individuals.”
From the field to the lab
Brush played as a middle linebacker, a position often regarded as the quarterback of the defense. In this position, he became accustomed to aiding teammates in grasping their roles on the field and ensuring everyone was properly aligned. At MIT, he quickly recognized that his role would shift.
“In high school, I was consistently reminding teammates of their responsibilities and assisting linemen who were incorrectly positioned,” Brush recalls. “At MIT, there was no need for that. Everyone was well aware of their duties. It was an incredible experience playing football with such an intellectually gifted group.”
Throughout his football journey, Brush mentions that concussions loomed over the sport. He was formally diagnosed with just one concussion, yet he highlights how challenging it can be to accurately identify concussions during games.
“We conducted baseline assessments before the season so we could use them to evaluate cognitive ability after a suspected concussion,” Brush explains. “However, as a player, you’re eager to return to the game and continue supporting your team, so athletes frequently minimize their injuries. The medical staff does their utmost to help.”
Brush transitioned to working as an accident reconstruction specialist right after graduation before joining a product design firm. It was in this capacity that he first collaborated with LIGHT Helmets on a consulting assignment, later taking on a full-time role with them last year.
Since joining, Brush has overseen research and development as well as the creation of new helmet lines, collaborating closely with LIGHT’s technology ally, KOLLIDE.
“I’m currently the sole engineer at LIGHT, so I juggle many different responsibilities,” Brush indicates.
A safer helmet
Brush directed the enhancement of LIGHT’s Apache helmet. His methodology was inspired by his favorite course at MIT, 2.009 (Product Engineering Process). During the prototype construction stage in that class, students often analyze the assembly of existing products. For Apache, Brush commenced by taking apart rival helmets to understand their operation, limitations, and the source of every ounce of weight.
“That process guided our choices on what to integrate into our helmets and what we deemed unnecessary,” Brush remarks.
LIGHT’s Apache helmets feature an impact-modified nylon exterior and a 3D-printed thermoplastic polyurethane lining. This liner can compress up to 80 percent of its thickness under full pressure, unlike conventional foam, which Brush states may compress only 20 to 30 percent at most. The lining consists of 20 distinct cylindrical pods, each exhibiting variable stiffness according to its position within the helmet.
Brush notes that the shell is more adaptable compared to traditional helmets, complementing a broader trend among companies that prioritize concussion prevention.
“The concept behind the flexible shell is that we can now compress both the inside and outside of the helmet, allowing us to prolong the impact duration and decrease the intensity of the hit,” Brush shares.
A winning formula
Brush states that the company’s performance in Virginia Tech’s evaluations has generated considerable enthusiasm within the industry. The Apache helmet is available across high school, collegiate, and professional levels, and the company is currently working on a youth version.
“Last year, we sold approximately 5,000 helmets, but we anticipate seeing growth by tenfold this year,” Brush notes. “Dealers recognize the chance to market the number-one-rated helmet at the price of many significantly lower-rated helmets.”
Additionally, other LIGHT helmets are presently being utilized at the highest levels, with players from 30 of the 32 NFL teams opting for a LIGHT Helmet when they gear up, according to the company. This progress has transformed Brush’s connection with football.
For example, he previously watched NFL games on Sundays only occasionally. However, now that his helmets are featured on television, he finds himself cheering for the players and teams wearing them.
Regardless of his preferred teams, when football becomes safer, everyone benefits.