I've never owned what I'd regard as a properly designed helmet, including the expensive Miller digital somethingorother I used today. My gripe is with the suspension system. I have to admit that they are better than they used to be since they made the ratcheting band contact the back of my head lower down than before, and the helmet is less apt to fall off my head. But the bad part is what I'll call the "drag" or "escapement" parts where the headgear pivots next to my temples. There are adjustment screws on either side, but I can fiddle and diddle them until the helmet is flipping down when I nod and not falling down when I put the helmet up. Well, they SORT OF work right. More or less. For a little while. But the adjustment of those two screws is touchy, hard to get in the sweet spot, the very small sweet spot.
The problem is easily solved, as should be obvious to any engineer or mechanic with any brains or experience. Those escapement sections with the adjusting knobs have a working diameter about the diameter of a quarter. If a decent engineer or mechanic were told to redesign them to make their operation less notchy and touchy, he would increase the size of that escapement to the diameter of a half-dollar, or better yet the diameter of a silver dollar. Since that section would not get any wider, there would be no problem fitting it under the same helmet. The added weight would be next to nothing. It would be FAR easier to dial in with the adjusters, would STAY in adjustment much better, would be far less subject to wear. The helmet would stay up until you wanted it down, then would come down all the way to the selected stopping point every time with one good nod of the head. Since the wearer no longer has to be pushing up the helmet because it's falling down, and/or no longer has to nod twice or pull the helmet manually down the last notch, the helmet no longer is falling off his head at unwanted moments. He wouldn't have to tighten the headband until his skull is compressed, just to keep the heavy helmet in place.
An utterly simple, cheap, and obvious tweak in the current suspension design would solve or at least hugely improve the decades-old problems of welding helmets.
But NOOOOOOoooooooo . . . . !!!!