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My guest for this bonus episode of the My Favorite Mistake podcast is Dr. Thom Mayer, one of USA Today’s “100 Most Important People in the NFL.” Thom serves as the Medical Director for the NFL Players Association, and he’s been at the forefront of player safety initiatives for years.
When he first joined us in Episode 274, we talked about leadership, learning from mistakes, and how he approaches systemic improvement in one of the world’s most physically demanding sports.
Now, we reconnect to follow up on one of the most closely watched experiments in pro football: the 2024 “dynamic kickoff” rule change. This initiative aimed to reduce concussion risk while maintaining the excitement of kickoff returns — and it worked.
What You'll Hear in This Episode:
- A 43% drop in concussions on kickoffs
- Kickoff return rates rising from 22% to 33%
- How the NFL balances data, safety, and entertainment
- Innovation in helmets and guardian caps
- What's next: reducing shoulder injuries with better gear
- Why “the work continues” is more than just a mantra
Dr. Mayer shares how physics, systems thinking, and collaboration between engineers, physicians, and players are shaping the future of football — while offering valuable parallels to employee safety in manufacturing and patient safety in healthcare.
“Why not half? Why not half as many concussions next year?” – Dr. Thom Mayer
“The good news is, it worked well. The bad news — and the good news — is that the work continues.”
Questions and Topics:
- How did the dynamic kickoff experiment play out during the 2024 NFL season?
- What were the outcomes in terms of concussion rates and kickoff returns?
- Are there plans for future adjustments or tweaks to the kickoff rule?
- How are guardian caps and helmet technology evolving to reduce injuries?
- What’s the difference between NFL guardian caps and those used at other levels of football?
- Can players still get concussions while wearing guardian caps?
- What are “guardian-cap optional” helmets, and how do they work?
- How is the NFL addressing the rise in shoulder injuries?
- Are there innovations coming in shoulder pad design or other protective gear?
- What parallels do you see between player safety in the NFL and safety efforts in manufacturing or healthcare?
- What’s your mindset around setting goals like “zero concussions,” and how do you stay motivated when perfection isn’t immediately achievable?
- Are there any new rule or equipment changes expected for the 2025 season?
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- Full transcript
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![“The good news is, [the dynamic kickoff] worked well. The bad news — and the good news — is that the work continues.”
Dr. thom
mayer](https://www.markgraban.com/wp-content/uploads/2025/05/Dr.-Thom-Mayer-My-Favorite-Mistake-Quotes-2.jpg)
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Episode Summary:
From Hypothesis to Helmet: How the NFL Is Making Kickoffs Safer
A Follow-Up Conversation with Dr. Thom Mayer, Medical Director for the NFL Players Association
In this special bonus episode of My Favorite Mistake, I welcome back Dr. Thom Mayer, one of the most influential figures in American football safety. Thom serves as the Medical Director for the NFL Players Association and was previously featured in Episode 274, where he shared stories about leadership, learning from failure, and his personal and professional commitment to continuous improvement.
This time, our conversation picks up with real-world data on a bold experiment we previously discussed — the 2024 “dynamic kickoff” rule change, a league-wide initiative designed to reduce concussions while preserving the excitement of one of the game’s most iconic plays. The stakes were high: maintain competitive integrity, delight fans, and most importantly, keep players safe.
A Play Worth Studying: The 43% Drop in Kickoff Concussions
Dr. Mayer shares that the early returns are not just promising — they’re encouraging. According to NFLPA and league data, concussions on kickoffs dropped by 43% during the 2024 season. At the same time, kickoff return rates increased from 22% to 33%, bringing more action back into the play without increasing risk.
Thom emphasized that this wasn’t just a lucky outcome — it was the result of a deliberate, systems-driven approach. The kickoff redesign was treated as a true scientific experiment: a hypothesis (that slowing down the “acceleration” in the force equation would reduce impact injuries) tested with real-world implementation. “We didn’t change the mass,” he said, “but we changed the acceleration.”
It’s a powerful case study in using data, feedback, and iteration to improve safety without compromising core performance. And it’s a story that resonates far beyond football — whether you work in healthcare, manufacturing, or any high-risk environment where improvement and safety must go hand-in-hand.
More Than Helmets: Innovation in Protective Gear
We also talked about the continued evolution of protective equipment. Helmets have changed dramatically over the years, but Thom points to the emergence of “guardian caps” — padded shells placed over helmets — as both a short-term and long-term safety enhancement. Some players now wear “guardian-cap optional” helmets, where the padding is integrated into the helmet’s design itself, eliminating the need for the external cap while maintaining protection levels.
Still, Thom is clear: “Can you get a concussion while wearing a guardian cap? Yes. But we’re always learning and adapting.” It’s not about declaring victory — it’s about relentless progress. His guiding motto? “Why not half? Why not half as many concussions next year?”
What Comes Next: Shoulder Pads, Data, and Continuous Improvement
While head injuries have received the bulk of attention in recent years, shoulder injuries are on the rise. Thom explains that today's players are bigger and faster, and while the league has implemented rules to reduce head contact, it’s naturally shifting the point of impact — often to the shoulders.
Future efforts, he says, will include rethinking shoulder pad design — possibly incorporating custom 3D printing and materials innovation — as well as using increasingly advanced video and biomechanical analysis to assess impact patterns and mitigation strategies.
Thom also draws parallels to other industries. “You’ve been in manufacturing, I’ve worked with health systems. It’s the same mindset. You set a goal of zero harm, even knowing that the journey won’t be linear.” That mindset — aspirational but grounded — is what keeps Thom and his colleagues pushing forward.
“The good news is, it worked well. The bad news — and the good news — is that the work continues.” – Dr. Thom Mayer
This episode is a must-listen for anyone interested in systems thinking, safety leadership, and learning from experimentation. Whether you’re managing a hospital, leading a production team, or running a football league, Thom’s insights apply across domains.