Unless the basic user needs are satisfied in safety helmets, it is difficult to get workers to wear them habitually and for long periods. Hotness, weight and fitting problems are major wearability issues that require improvements. The enormous need for an optimally designed helmet in China prompted a case study on comfort aspects in helmets. The subjective impressions of the wearers of test helmets provided useful information for design changes to improve comfort. The heat transfer measurements through helmets indicated the need for ventilation openings to be provided on the shell of plastic helmets. Due to the advantage of low weight and good ventilation, it is recommended that cane helmets be further developed to improve protection, wearability and durability, and subsequently be produced in large scale.