In molten metal operations, where radiant temperatures can exceed 2,000°F, face and eye protection is not simply best practice—it is a critical requirement for worker safety and regulatory compliance. OSHA mandates appropriate personal protective equipment (PPE) for employees exposed to thermal hazards, while ANSI Z87.1 establishes rigorous performance criteria for eye and face PPE used in these extreme environments. Yet despite advancements in many areas of PPE, cap bracket systems have remained largely unchanged—until now.
Paulson Manufacturing is proud to announce the launch of AylonTM, a proprietary material innovation designed to elevate the performance, durability, and usability of face shield mounting systems in high-heat applications.
Why Cap Brackets Matter
While face shields and visors often receive primary attention, the cap bracket system plays a crucial role in ensuring consistent protection. A failure at this connection point—whether due to heat degradation, mechanical weakness, or user error—can compromise the entire protective system.
Historically, molten metal environments have forced a compromise:
- Traditional thermoplastic cap brackets lack the heat resistance required and degrade under sustained radiant exposure.
- Aluminum brackets, while heat-resistant, introduce ergonomic and comfort challenges, including difficult installation, pinch-point hazards, and poor balance.
These trade-offs have persisted—not because they are effective, but because there has been no viable alternative.
AylonTM: Engineered for Extreme Heat
AylonTM is a specialized composite material that integrates aluminum particles within a nylon matrix, delivering both thermal reflectivity and structural resilience in high-temperature environments.
This innovation enables AylonTM cap brackets and components to perform reliably where conventional plastics fail, while avoiding the usability drawbacks associated with metal systems.
Key Features and Performance Benefits
Some of the key features and benefits of AylonTM include:
- Superior Heat Resistance: AylonTM reflects radiant heat and maintains its structural integrity in the presence of molten splash and sustained high-temperature exposure—making it suitable for steel mills, foundries, and similar operations.
- Simplified Attachment with Reduced Risk: The press-to-release slotted cap adapter system allows workers to quickly attach and remove brackets from hard hats—without excessive force or complex manipulation. This design significantly reduces the risk of hand and finger injuries commonly associated with metal spring systems.
- Elimination of Pinch Points: Unlike aluminum brackets with exposed tension mechanisms, AylonTM brackets are engineered with worker safety in mind, eliminating pinch hazards during routine use.
- Ergonomic Weight Compensation: An integrated weight-balancing design improves load distribution when the face shield is in the stowed position, reducing neck strain and increasing comfort during extended wear.
- Internal Shield Attachment System: AylonTM brackets feature an internal window attachment design, eliminating external cam locks that are prone to melting or failure under extreme heat. This enhances both durability and reliability in critical applications.
- Fully Integrated High-Performance Components: Complementary AylonTM components—including washers, rivets, and pivot screws—ensure consistent thermal performance across the entire system.
Compliance and Confidence
For safety professionals, maintaining compliance with OSHA regulations and ANSI Z87.1 standards requires more than selecting certified face shields—it demands confidence that every component of the system will perform under real-world conditions. AylonTM enhances system integrity by addressing one of the most vulnerable links in high-heat face shield configurations.
A New Benchmark in High-Heat Face & Eye Protection
AylonTM represents a fundamental shift in the design philosophy of face shield systems: no longer must organizations choose between heat resistance and usability. With AylonTM, both are engineered into a single, purpose-built solution.
For more information on our proprietary AylonTM heat reflective material and how it can benefit your mill or foundry operations, contact us today.
In Part 2 of this series, we will introduce Paulson’s upcoming HeliosTM heat-reflective face shield technology, which advances face protection further by delivering high-performance reflectivity—without the use of high-cost gold coatings.
