Football and aviation (pilot) helmets were constructed of leather.
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Modern US army helmets are made from Kevlar.
They started wearing helmets when a guy got tackled and he got an injury so they decided to make an invention that protects your head from you getting hurt. It's made of hard steel so when you bump into somebody you don't get an injury. That's when they started making helmets......
These quality helmets are made in the country of Korea. They are made from composite resins and are precision made. They are extremely durable and light.
depends on the helmet. Its just plastic on the outside, it is the shape that helps to dispense impact. Inside there can be a variety of materials. Foam and Styrofoam are in most of the low end helmets, while a lot of the pro helmets have an air cushion system. The "plastic" is polycarbonate.
Most WW2 era helmets are made by a drop hammer forge. A plate of steel is laid over a form and a heavy hammer pounds it into the shape of the template. The M1 helmet has a thin metal seam formed around the edge so that it will not be sharp. The fitting for the chin strap is welded on. Most helmets of other countries are made in similar fashion. Of course the German helmet is thicker steel as it does not have a liner. The French Adrian helmet is made of 3 pieces that are formed and welded together.