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

System Architecture

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

Questions?