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This paper presents the redesign of an industrial safety helmet shell to improve its thermal properties. First an experiment was established to simulate the conditions of a head wearing a helmet. The average temperature beneath the helmet shell, the speed of heat dissipation through convection, and the temperature contour beneath the helmet shell were used to describe the thermal properties of a helmet. Helmets of different types and makes were tested, and various design concepts were examined. Design suggestions for improving thermal properties of industrial safety helmets were made. According to these design suggestions, a new design prototype was developed, tested, and further modified. The thermal properties of our final helmet shell design have improved over the commercially available helmets we tested. It also passed the weight, impact, and penetration tests of the Chinese National Standards …