CASE STUDY

Barrier helmet — a shared response to the needs of the pandemic

At the start of the pandemic, a doctor and researcher approached WATS with a need to develop a barrier helmet. We brought together the medical team’s knowledge and our experience in manufacturing gas-tight structures. The collaboration led to series production at a time when hospitals needed new solutions.

UCK Warszawskiego Uniwersytetu MedycznegoMedycyna / MedicalSafety & rescue

Helmet and equipment shown in a hospital room.

01 / Project story

The challenge

The starting point was a specific hospital need: a helmet designed to work with oxygen equipment and an early-warning system. User comfort and the day-to-day work of clinical staff were important design considerations. The medical brief had to become a construction suitable for repeatable manufacturing.

02 / Project story

The solution

Together, we developed a barrier helmet using WATS’s experience in joining thermoplastic materials. Project documentation identifies thermoplastic polyurethane (TPU) and high-frequency (HF) welding. A transparent chamber, collar, ports and fastening components formed a construction intended to work with the associated equipment. Photographs from April 2020 show demonstrations of the helmet and details of its construction.

03 / Project story

The outcome

We launched series production of the helmets during the pandemic. The project combined the medical team’s work with WATS’s manufacturing capabilities, turning a need into a finished device. A key project record is the decision of the President of Poland’s URPL dated 6 April 2021, issued at the request of the University Clinical Centre of the Medical University of Warsaw. It permitted that institution to put 300 WATS-manufactured barrier helmets for ventilation of patients with COVID-19 into use in 2021.

Step by step

The process.

A need from the hospital

At the start of the pandemic, a doctor and researcher approached WATS. Discussion of user and staff needs initiated the joint project.

Joint development

We combined the medical team’s knowledge with WATS’s experience in thermoplastic materials and gas-tight structures.

Manufacturing and demonstration

Photographs from April 2020 document the helmet, ports and demonstrations with connected equipment.

Production during the pandemic

Development of the construction led to series production.

A documented project milestone

The decision dated 6 April 2021 covered 300 WATS-manufactured helmets to be put into use by UCK WUM in 2021.

Manufacturing experience applied to a new field

This project shows how knowledge of materials and gas-tight construction can support specialists in another field. WATS worked with the medical team to develop and manufacture the construction and launch production.

Material and manufacturing method

Project element	Solution
Material documented for the project	Thermoplastic polyurethane (TPU)
Joining method	High-frequency (HF) welding
Construction shown in the photographs	Transparent chamber, collar, ports and straps
Manufacturing outcome	Series production during the pandemic

Questions about the project

Who did WATS work with?

The project was developed with a medical team. The formal documentation names the University Clinical Centre of the Medical University of Warsaw.

What does the figure of 300 helmets mean?

It is the number of devices covered by the decision of 6 April 2021, not a statement of the total number manufactured or delivered. The decision concerned a specific institution and the year 2021.

Where can I learn about WATS’s manufacturing methods?

Explore our technologies and other custom manufacturing and OEM projects.

This account describes a historical pandemic-era project. It draws on WATS’s account, archival photographs, technical descriptions and decision UR.D.WM.DNB.27.2021.

Details and perspectives