P1550 Customized Personal Protection Headwear
Chris Casella (Project Leader & BME), Scott Quenville (ME), Nate Marshall (ME), Tiffany Gundler (BME), Christian Blank (ME), Kayla
Wheeler (BME)Denis Cormier (Sponsor & Customer)
John Kaemmerlen (Guide)
Agenda
● Project Description● Concept Summary● System Architecture● Design Summary● System Testing Results● Objective Project Evaluation● Opportunities and Suggestions
● CAD models of different 3D printed cellular materials
● Semi-automated workflow for sending scanned dimensions to SolidWorks to the 3D printer
● 3D printed, customized, energy absorbent pads● Custom fitted football helmet with pads● Drop test rig with impact sensor feedback
Project Description
● ~45% Density padding for energy absorption
● ~25% Density for comfort● Densities variable to accommodate
applications● Performed similarly to Production
helmet with room to improve
Concept Summary
Padding:Padding design modeled off of market designNew shapes were created per restrictions of the makerbotTest Rig:Modeled off of NFL test rig (NOCSAE)
Design Summary
System Testing Results
● Our padding significantly comparable to padding on market● Performance increase with customized headform
System Testing Results Cont.
Tukey Pairwise Comparisons
Grouping Information Using the Tukey Method and 95% Confidence
Factor N Mean GroupingOur Padding 15 75.333 ASchutt 15 74.733 A
Means that do not share a letter are significantly different.
Objective Project Evaluation
● Designed & printed padding● Designed & assembled test rig● Tested padding inserted into helmet● Created workflow procedure● Need more testing and more
accurately shaped headform for drop testing
Performance vs Requirements
● Time of 3D Printing Process/Foam Thickness: Should have done more analysis before setting target value
Opportunities and Suggestions
● Purchasing smaller helmet● Higher density padding● Printing padding in different sections● Better Attachments ● Custom fit padding to head form
Opportunities and Suggestions cont
● Potential Patent Opportunity● More testing with durability and temp● Experiment with more designs● Better printer modifications● Better head-helmet merge