The foot is made up of 26 bones, 33 joints, 107 ligaments, 19 muscles, and numerous tendons, all working together to support movement and balance. When these structures are properly aligned, they help absorb force and keep workers moving safely through demanding jobs – but when even one part is injured, mobility and stability can quickly break down.

Now let’s consider the metatarsal region, which is where the top of the foot connects down to the toes – this area is especially vulnerable to impact and compression injuries. Dropped tools, falling materials, or rolling equipment can easily cause fractures, soft tissue damage, and long recovery times.

That’s why metatarsal protection in safety boots is critical. At HexArmor®, we use D3O® technology in our metatarsal protection – a highly advanced material that delivers lightweight yet substantial safety to the top of the foot. More on that later.

In the meantime, we’ve compiled a list of frequently asked questions to give you everything you need to know about top-of-foot protection.

Metatarsal protection FAQs

What does metatarsal protection mean?

Metatarsal protection refers to footwear or guards designed to protect the metatarsal bones in your foot. These are the long bones across the top and middle, just behind the toes. This type of protection is most often used in the workplace to guard against heavy impacts.

What are metatarsal guards, and where are they located?

Met guard boot plates are designed to protect the top of the foot from sudden impact, helping reduce injury risk before an incident occurs. Usually made from metal, composites, or advanced polymers, metatarsal foot guards can be found internally or externally on a work boot.

• Internal met guards are built directly into the boot, often beneath the laces.
• External met guards are hard shells attached to the outside of the boot, sitting over the laces.

Met guards usually work alongside a safety toe to extend protective coverage from the top of the foot down to the toes.

Why is metatarsal protection important?

Metatarsal injuries are among the most serious foot injuries in industrial environments, often requiring extended healing and limiting a worker’s ability to return to the job. These injuries resulting from top-of-foot impacts can be significantly decreased with use of work boots with met guards.

Understanding how metatarsal protection works and when metatarsal safety boots are needed is essential for keeping workers protected and on their feet.

What jobs require metatarsal protection?

Met guards in work boots are mostly required in any environment where injuries to the metatarsal bone can occur, such as tasks with "substantial risk" of impact or crush injuries from heavy items. This could be lifting or rolling heavy objects, especially those made of metal, like beams, pipes, or rolling drums.

• Tasks: Loaded drums, moving vehicles, scaffolding, heavy tools, or construction material.
• Weight thresholds: It is generally recommended when there is a risk of objects weighing 30lbs. or more being dropped, or 50lbs. or more being rolled onto the foot.
• Industries: Construction, manufacturing, warehousing, foundries, and other heavy industry roles.

Evaluate jobsite hazards through a risk assessment to determine whether metatarsal protection is required.

How does metatarsal protection on footwear work?

Depending on the material used, met guards are designed to do one of two things during an impact: either absorb the impact or deflect the impact.

Harder materials like metal or composite deflect heavy items away from the foot's vulnerable top area.

Materials like D3O® or specialized polymers flex on impact, turning solid to absorb and dissipate energy, then return to their flexible state.

What standards are associated with metatarsal protection?

Protection must meet safety standards that require specific impact resistance for hazards like falling objects in manufacturing, foundries, or welding environments. Here are the two main standards:

ASTM F2413 (United States): The main U.S. performance standard for protective footwear includes three ratings for met guard coverage: 75, 50, and 30 foot-pounds of protection. Most employers recommend Mt/75 met guard boots. The number means they resist that number in pounds of impact from a one-foot drop, like Mt/75 boots offer protection from a 75-pound object falling from a height of one foot.

CSA Z195-14 (Canada): The Canadian standard that uses a similar test, dropping a 50-pound bar from 18 inches to create a 75-foot-pound impact on the metatarsal area, requiring a full inch of clearance inside the boot.

What is D3O®?

D3O® is a brand of smart material used for impact protection, known for being soft and flexible normally but instantly hardening upon impact to absorb and dissipate energy, protecting the wearer from shock.

This non-Newtonian substance, made of polymers, allows for lightweight, comfortable gear that becomes tough when needed, finding use in motorcycle gear, electronics cases, military equipment, and workwear.

Unlike Newton's law of viscosity, where viscosity remains constant, D3O's viscosity changes based on the force applied.

What is D3O® Metatarsal Protection and how does it work?

Metatarsal guards that include D3O® impact-resistant technology absorb and disperse energy from heavy impacts, helping shield the top of your foot from dropped tools or equipment.

Unlike rigid materials, D3O® stays soft and flexible as you move, then instantly stiffens on impact. This advanced material helps absorb up to 100 joules of energy – the impact level used in EN ISO 20345 safety footwear testing – without sacrificing all-day comfort.

The absorptive material has an impressive ability to harden its structure during a sudden impact, immediately slowing the velocity of the impact and displacing its energy.

Why are D3O® protectors better than hard armor?

D3O® impact protectors are inherently soft and flexible. Because of their high-performance levels, they can also be lower profile and less bulky, making them more comfortable to wear. D3O® delivers the best protection on the market and consistently outperforms traditional foam-based protection.

HexArmor® can help

Our safety boots were made to solve real safety problems. We’ve created specialized safety footwear – the first ever by a safety manufacturer – with field-inspired design, out-of-the-box comfort, and our signature Wearability® in every pair – because we know the pros need the best.

When it comes to top-of-foot protection, HexArmor® integrates D3O® technology into our met guards to deliver advanced impact absorption without sacrificing flexibility or comfort. This innovation allows us to set a higher standard for protective footwear, helping safety professionals choose solutions that protect workers while supporting all-day wearability.

Learn more about our safety boot technology here.

Let us know if you have questions or would like to start a trial – our Solution Specialists are ready to work with you. Call 1.877.MY ARMOR or send us a message.