1. 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)

2. Agenda ● Project Description ● Concept Summary ● System Architecture ● Design Summary ● System Testing Results ● Objective Project Evaluation ● Opportunities and Suggestions

3. ●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

4. ● ~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

5. System Architecture

6. Padding: Padding design modeled off of market design New shapes were created per restrictions of the makerbot Test Rig: Modeled off of NFL test rig (NOCSAE) Design Summary

7. System Testing Results ● Our padding significantly comparable to padding on market ● Performance increase with customized headform

8. System Testing Results Cont. Tukey Pairwise Comparisons Grouping Information Using the Tukey Method and 95% Confidence Factor N Mean Grouping Our Padding 15 75.333 A Schutt 15 74.733 A Means that do not share a letter are significantly different.

9. 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

10. Performance vs Requirements ●Time of 3D Printing Process/Foam Thickness: Should have done more analysis before setting target value

11. Opportunities and Suggestions ●Purchasing smaller helmet ● Higher density padding ● Printing padding in different sections ● Better Attachments ● Custom fit padding to head form

12. Opportunities and Suggestions cont ● Potential Patent Opportunity ● More testing with durability and temp ● Experiment with more designs ● Better printer modifications ● Better head-helmet merge

13. Questions?