This week, at the ASDA 2025 defense expo, Croatian defense manufacturer Šestan-Busch unveiled what it claims is the world’s first military helmet capable of withstanding a direct hit from 7.62mm ammunition — a potential game-changer on modern battlefields.
With over three million helmets sold across more than 80 countries, Šestan-Busch is no stranger to innovation. However, company director and owner Alojz Šestan says this latest product represents their most significant technological achievement to date.
A Helmet Designed for the Realities of Modern Warfare
Traditionally, military helmets are designed to protect against shrapnel and pistol rounds — threats commonly encountered in combat. But the nature of warfare has evolved. Rifle rounds, especially the 7.62mm caliber used in AK-47s, have become one of the most lethal dangers soldiers face today.
“Conflicts around the world have shown us that protection against shrapnel isn’t enough anymore,” explains Šestan in an exclusive interview with CombatOperators.com. “Today, for the first time, we’re presenting a helmet that protects soldiers against threats at Level 4 — specifically, Kalashnikov fire.”
According to Šestan, the push for such a helmet came directly from their military clients, who repeatedly asked when the company would develop protection against 7.62mm rifle rounds. “It’s rare you’ll see someone fire an AK-47 from just a few meters away, but the risk is always present. Our goal was to offer soldiers a better chance of survival in those worst-case scenarios,” he said.
A Long Journey of Innovation
Šestan-Busch has been a key player in the protective equipment industry since 1994, when the Croatian company Šestan merged with the German company Busch. Since then, they’ve been developing helmets and ballistic gear for some of the world’s top armed forces.
But achieving this level of ballistic resistance wasn’t easy.
“We tried everything — ceramics, new materials — but the helmets ended up being too heavy for practical use,” says Šestan. “Eventually, working with our German partner and a Canadian firm, we developed a brand-new composite material that finally made it possible.”
This proprietary composite allowed them to produce a helmet that not only stops a 7.62mm round but also remains light and wearable in combat conditions — a first in the global defense industry.
Competing on the Global Stage
Šestan points out that companies from smaller countries often have to work twice as hard to prove themselves in a market dominated by big players. “It’s not easy competing with global giants. We have to offer the same — or better — quality while constantly innovating.”
He also notes the growing challenge of counterfeit products, especially from China. “Some Chinese manufacturers have been selling knockoff helmets with fake Šestan-Busch labels, particularly in Ukraine. They even undercut prices by 30%, which creates unfair competition.”
Despite these challenges, Šestan-Busch continues to push the boundaries of what’s possible in personal ballistic protection — and with their latest helmet, they may have just set a new global standard.
