Using 3D Scanning for Improved Helmet Design

Abstract

One-size-fits-all' is definitely not a good approach to helmet design, especially for situations with the significant risk of head injury such as sports and industrial workplaces. Function of helmets is only given with perfect fit. But the complex geometry of heads was insufficiently defined by traditional measurement which captures length, width and circumference only as numerical values. Therefore, no head shape information was available so far. In contrast, 3D scanning-technology provides an innovative approach for analyzing head measurements and shapes. Scientific analyses show remarkable variations in head shapes of humans within the same head circumference. Despite the real need for head protection systems, no reliable anthropometric German head data of women, men and children was available so far. The results of the Hohenstein R&D project "Textile-based head protection systems"(IGF 16976 N) close this information gap. To collect exact three dimensional head data a specific scanning process was installed, heads of men, women and children were scanned and a database of 3D scan head data was created. Statistic evaluations as well as 3D shape analysis were conducted. Market share tables and virtual 3D shape models representing realistic head shapes of German population were generated and new innovative virtual 3D analysis methods for proving fit and ergonomic comfort were developed. 3D scanning-technology provides an innovative approach for the optimization of helmets in consideration of fit, functionality and design. In summary, the study results provide fundamental guidelines for helmet optimization in consideration of fit, functionality and design.

Quantitative Fit Assessment for Smart Gloves

“…While early 3D scan-based fit analysis was limited to qualitative, morphological visualizations [43], quantitative distance measurements between the garment and the body have been developed by overlaying clothed and unclothed body scans [18]. Previous studies have used clothed/unclothed scan overlays to measure the distance between functional clothing and the body surface using cross sectional analysis and mesh deviation analysis, which quantifies the garment-body dimensional offset, or air gaps [17], [19], [20]. Researchers have validated mesh deviation analysis methods by scanning wet clothing with distinguishable contact areas [44] and by exploring air gaps in specific areas, or 'zones,' referred to as zone analysis [17], [20].…”

Procedure for Determining Dimensional Allowances for PPE Using 3D Scanning Methods

“…For many years now, 3D scanning technology has brought benefits in the area of ergonomic design of protection devices. Contemporary research mostly concentrates on rendering the shape of the human body with the aim of improving the fit of PPE [ 14 , 15 , 16 , 17 , 18 , 19 ] as researchers determine the so-called internal dimensional allowances to improve the fit of PPE in accordance with the anthropometric traits of individual users.…”

Photogrammetry: An accurate and cost-effective three-dimensional ice hockey helmet fit acquisition method

“…Fit is an important parameter to consider when designing protective equipment, and morphological differences have been shown to greatly affect fit. 9,10 Anecdotally, headgear and facial wear (glasses, oxygen masks, helmets, etc.) have been known not to fit the East-Asian population when designed by European and North American companies.…”