This research paper focuses on the design and development of an affordable, lightweight, and ergonomically optimized industrial safety helmet that complies with inter- national standards such as ANSI Z89.1 and EN 397. The objective is to enhance workplace safety for individuals in high-risk zones using advanced materials and simulation-based de- sign. The outer shell was manufactured using a carbon fiber-reinforced polymer (CFRP) com- posite to minimize weight while maximizing impact resistance. The design process incorpo- rated Quality Function Deployment (QFD), benchmarking of commercial helmets, and deci- sion matrices to identify the most viable concept. Physical compression testing after the fab- rication of the final prototype was conducted using a Tinius Olsen machine, while SolidWorks static test simulations verified its ability to withstand loads significantly exceeding 8.636 kN, surpassing regulatory requirements. Additional design considerations included ventilation, modular accessory compatibility, and optional smart features such as impact sensors. A cost analysis demonstrated a competitive production estimate of 14.400 KD, supporting industrial scalability. The results confirm that the proposed helmet design satisfies performance, safety, and economic expectations, offering a reliable solution for next-generation personal protec- tive equipment (PPE) in construction and manufacturing environments.