Welding Helmet Features Explained: Lenses, Fit and PAPR

A welding helmet is an essential part of welding PPE. Its filter and shell must suit the radiation, sparks and other hazards of the work.

An ordinary welding helmet does not filter smoke or welding fumes. Respiratory protection and fume extraction require separate selection.

But what makes a welding helmet ‘good’? We’ve covered all the features you should be looking for in your next welding helmet.

Safety Standards

When looking for a welding helmet, the first thing you should check is the safety standards. If the helmet you’re looking to purchase doesn’t meet the regulations of your region, it’s not a good helmet.

Check the helmet and filter's documented protection. AS/NZS 1338.1 concerns welding filters; AS/NZS 1337.1 concerns eye and face protection. Verify the actual impact classification rather than treating a standard number as proof of high-impact protection.

Confirm that the model's certification and markings meet the requirements for the task and location. Do not assume different standards are interchangeable.

Auto-Darkening vs Passive Helmet Lenses

What is a passive helmet?

A passive lens welding helmet comes with a lens that uses UV and infrared coated glass that is tinted to a set shade, usually shade #10. These helmets don’t change shades, so they need to be flipped up when you’re not welding to be able to see.

That means when prepping the weld joint, positioning the torch or inspecting the weld, the helmet needs to be up. It can be flipped down by flicking or nodding your neck, allowing it to fall back into place so you can strike an arc.

There are a few problems associated with passive helmets.

First, it can be difficult to keep the torch perfectly lined up while getting the helmet back into place, especially if you’re still learning to weld.

A passive filter has a fixed shade in use, but an approved filter of another shade can be fitted where the helmet design permits it. Select the shade for the process and current.

Third, the constant up and down of the helmet can put a serious strain on your neck. For any kind of tack welding or small sections, having to flip your helmet up every single time can really take its toll.

When you’re welding day in, and day out, that kind of stress on your neck can lead to injuries.

What is an auto-darkening helmet?

An auto-darkening helmet has a lens that tuns ‘on’ and ‘off’. When you’re not welding, and no arc is detected, the helmet’s lens will be shade #3 or #4 (depending on the brand).

When a suitable arc is detected, the filter switches to its selected dark shade. Available light and dark shades vary by model.

There are two types of auto-darkening helmets available on the market: fixed or variable.

Fixed auto-darkening helmets

A fixed auto-darkening helmet has a similar lens to a passive lens helmet. While it can change from light to dark, it only has one ‘dark’ shade, generally shade #10 or #11.

They remove the issue of neck fatigue and strain, as you won’t have to constantly take it off to check your weld, but they’re still not suitable if you’re welding at an amp range that isn’t covered by its pre-set shade.

Variable auto-darkening helmets

A variable filter lets you select among its supported dark shades. Select the correct welding or cutting shade from the manual; grind mode is a separate operating mode.

An auto-darkening helmet still needs inspection, correct settings and reliable detection. Stop welding if the filter fails to darken as expected.

If you’re going to get yourself a variable auto-darkening helmet, there are a few other things to consider.

Optical Clarity Classifications

EN 379-marked filters use four optical classifications, scored from 1 to 3 with 1 the highest class. Other applicable standards may use different markings; these are not universal numbers on every helmet.

Optical class: how distorted is the image through the lens? If you look through the lens, and it’s like looking through rippled water, then it’s not a good helmet. The image should be clear and crisp to obtain a 1 rating.

Diffusion of light class: are there impurities in the lens from the manufacturing process? These impurities make the lens unclear and hard to see out of, like fingerprints or scratches on glasses. The lens should be uniform and clear to obtain a 1 rating.

Variations in luminous transmittance class: focuses on the lens’s adjustable shade function. Once a shade has been selected, how consistent is it across the lens? A quality lens will be the same shade up or down, left to right, and in the corners. There should be no areas that are too bright or too dark, as this affects the optical clarity. An even shade across the entire lens is needed to obtain a 1 rating.

Angle dependence on luminous transmittance class: there should be a clear view with no stretching, dark areas, blurriness, or problems when looking at an angle. This is similar to variations in luminous transmittance. It measures the consistency of the shades across the lens but at an angle. It should look the same downwards or upwards as it does straight through to obtain a 1 rating.

A 1/1/1/1 marking is the highest result in those four EN 379 categories, not a complete assessment of fit, protection or suitability.

Shade Range

What is the shade range of the helmet? The shade range is how light or dark the helmet filter can get. The higher the number, the darker the shade.

It’s important to find a balance between adequately protecting your eyes while still clearly seeing your workpiece.

Check the actual filter's available shade range and light state; these vary between helmets.

Select shade using the process-and-current chart. Do not choose protection from apparent brightness alone.

Low-current TIG needs reliable arc detection as well as an appropriate shade. A 9–13 shade range alone does not tell you the helmet's minimum TIG detection current.

Start with adequate darkness and adjust within the recommended range for the task; never go below the required protective shade just to improve visibility.

Lens Sensors and Reaction Time

How many arc sensors does the helmet have? Most helmets will have between two and four sensors on them. Entry and hobby level helmets will generally only have two, while industrial level helmets will have up to four.

These sensors are what detect the welding arc and trigger the darkening in the lens. The more sensors you have, the better the coverage, which can be needed for any out-of-position welding that might obstruct some.

How fast does the lens react? The lens reaction time or switching speed is how quickly the lens goes from light to dark when it detects the arc.

Compare switching performance within the stated temperature and operating limits. A quoted switching time alone is not a universal professional-grade threshold.

View Size

How big is the lens? Being able to see what you’re doing while you’re welding is essential, so you’ll want a helmet with a lens that’s big enough.

The lens size you get will mainly come down to personal preference, but a bigger lens can be beneficial if you’re welding out-of-position.

Adjustable Settings

Depending on the helmet you get, they may have the ability to change the lenses sensitivity and delay times.

Sensitivity adjusts how readily the sensors respond. Use the manufacturer's guidance for low-current arcs and ambient lighting; more sensitivity is not automatically better outdoors.

Delay: how quickly the helmet goes from dark to light. A short delay means the lens will lighten quickly, while a long delay will mean the helmet stays dark for longer. An increased delay is used a lot with pulse welding, as you don’t want the helmet to lighten as the arc fades during the cycles. If you were doing a lot of tack welding, a short delay would be great.

True Colour Lens Technology

Does the helmet have true colour, or is it green? True colour means that more colours from the spectrum can pass through the lens (more reds and blues, less greens) for better optical clarity. It eliminates the green hue that is typical of some older welding helmets.

Assess visibility and comfort with the actual filter. A colour-view feature alone does not prove reduced fatigue or longer safe working time.

The ELITEVISION technology in UNIMIG helmets allows for a true colour view.

Comfort and Fit

How comfortable is the helmet? When you’re welding, especially if it’s for long periods, comfort is essential. The harness on the helmet is what makes them comfortable. You can get 3-point, 4-point and 5-point harnesses.

Try the adjusted harness for stability, balance and compatibility with other PPE. More adjustment points do not guarantee a better fit on every head.

Batteries and solar assistance

Is the helmet solar powered? Does it come with a replaceable battery?  

Auto-darkening filters use different power arrangements. Some combine solar cells with replaceable batteries; passive filters do not need power.

Check battery condition and the filter's test procedure before use. Solar assistance does not mean the filter cannot fail.

Confirm the battery type and replacement instructions for the model. Do not assume solar cells recharge its battery.

Where a replaceable cell is specified, fit the correct type and polarity.

Follow low-battery warnings and stop using a malfunctioning filter. Do not rely on an assumed backup battery to maintain the dark state.

Grind Mode

Grinding creates impact and flying-particle hazards. Select eye and face protection for those hazards separately from welding-filter performance.

Grind mode holds the filter in a light state rather than responding to an arc. Its shade and controls are model-specific.

Use the helmet for grinding only if its complete configuration has the required impact protection, with the specified safety glasses underneath.

Return to welding mode and check the setting before striking an arc.

Magnifying ‘Cheater’ Lens

Mag (or cheater) lenses let you zoom in and get a closer view of your weld. They insert over the lens inside the helmet and work the same way that a standard magnifying lens does.

A compatible magnifying insert can help with close work, but it is not automatically a substitute for prescribed corrective or safety eyewear.

Respirators and Other PPE

Can you fit other pieces of PPE under the helmet? A welding helmet isn’t always the only piece of PPE that you’ll need to protect your face with.

Select respiratory protection for the identified contaminants and exposure, alongside suitable fume controls. A respirator protects only against the hazards for which its filters and complete system are approved.

While welding helmets offer ample protection, it is still recommended that safety glasses be worn underneath for an extra layer of shielding for your eyes.

A lot of welding helmets sit flush against the face, making it impossible to wear respirators or safety glasses without the helmet sitting funny and exposing the front of your neck. If you’re planning to have any added protection, make sure it fits.

PAPR Helmets

A PAPR may be appropriate for some welding-fume exposures when selected through a respiratory-protection assessment. It does not supply oxygen and is not suitable for oxygen-deficient atmospheres. A confined-space assessment must determine the controls required.

A PAPR uses a powered blower to supply filtered surrounding air to an approved headtop or facepiece.

A PAPR draws surrounding air through its fitted filters. Protection depends on the approved respirator, filter type, contaminant and operating conditions; a particulate filter does not remove every gas or vapour.

A loose-fitting welding headtop uses maintained airflow and the specified face seal or shroud; it is not an airtight helmet. Fit and maintain every component as instructed.

Check airflow, alarms, battery, filters and hose before use. Use only an approved combination of blower, filter and headtop.

Compare the complete PAPR system's approved protection and welding features; do not assume all configurations have the same rating.

UNIMIG Helmets

Check suitability for each intended process on the exact UNIMIG model, including shade range, minimum TIG current and grinding approval.

Common controls to compare include:

• Weld/Grind – weld mode or grind mode
• Shade – select the shade needed for your type of weld
• Sensitivity – how sensitive to the light your helmet is
• Delay – how long the filter remains dark after the arc stops

Optical class, shade range and controls vary by model and generation.

Use the current model manual for specifications. The TOXIC, CHAOS and RWX6000 examples below are older products, not a statement of the current helmet range.

Reference diagrams: UNIMIG. Original source attribution is retained.