A toe cap having at least one end wall (12) extending in an arch shape, and a cover wall (14) extending therefrom that covers the toes on the upper side, wherein the cover wall and the end wall have a base wall thickness G, and areas separated from sections of the walls, such as webs in the walls, have a thickness D with 0D<W, wherein the difference between the volume of the toe cap with areas filled to the base wall thickness W and the volume of the toe cap with the areas of lesser thickness is 5% to 35%, and/or the difference between the area of the toe cap with filled areas and the outer surface of the toe cap without the areas is 20% to 60%.

A toe cap having at least one end wall (12) extending in an arch shape, and a cover wall (14) extending therefrom that covers the toes on the upper side, wherein the cover wall and the end wall have a base wall thickness G, and areas separated from sections of the walls, such as webs in the walls, have a thickness D with 0D<W, wherein the difference between the volume of the toe cap with areas filled to the base wall thickness W and the volume of the toe cap with the areas of lesser thickness is 5% to 35%, and/or the difference between the area of the toe cap with filled areas and the outer surface of the toe cap without the areas is 20% to 60%.

A protective device, in particular a safety toe cap, for use with an article of footwear is provided. A safety toe cap of the present technology includes one or more strain hardened portions configured to strengthen or reinforce sections of the safety toe cap against impact, particularly from above. The one or more strain hardened portions have increased strength in relation to adjacent non-strain hardened portions and therefore may maintain adequate protection of a user's toes and foot, while simultaneously allowing for lowered material use and a device with a lightweight, streamlined profile.