Team Leader: Chris Casella Nate Marshall Tiffany Gundler Scott
Quenville Christian Blank Kayla Wheeler P15550: Customized Personal
Protection Headwear Preliminary DDR
Slide 2
AGENDA Background General Information Current Product
Additional Deliverables Stakeholders Problem Definition Customer
and Engineering Requirements Benchmarking Specifications System
Analysis House of Quality Functional Decomposition Systems Design
Alternatives Considered and Pugh Charts System Architecture
Engineering Analysis Weeks 9-12 Update Expert Advice Test Rig
Design and Pugh Chart Test Plan and Results Preliminary Workflow
Project Planning Risk Management Updated Project Plan
Slide 3
PROBLEM STATEMENT Current State: Limited to manufactured
helmets in contact sports Desired State: Custom Fit helmets using
3D printed Thermoplastic Urethane (TPU) as the padding to absorb
energy from the impact Project Constraints: Overall helmet weight
(benchmarked against competitors) Durability (Target Age: 15-25)
Manufacturability Biocompatability $1000 budget Key Goals and
Deliverables 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
Slide 4
BACKGROUND
Slide 5
1.6-3.8 million sports related head injuries in the U.S. 2012 -
261 diagnosed concussions o.81 conc/game 2013 - 228 diagnosed
concussions o.71 conc/game Repeated head injuries result in Chronic
traumatic encephalopathy On august 29th, 2013 a lawsuit was taken
against the NFL for a total of 765 million dollars. Manufacturers
Include: Riddell, Schutt, Rawlings, and Xenith.
Slide 6
CURRENT PRODUCT- Schutt ION 4D Adult Football Helmet The new
Schutt helmet uses a unique facemask design that allows easy
removal Uses Thermoplastic Urethane (TPU) padding that allows for
higher cushioning value Scored better ratings in impact testing
than the Xenith X1
ENGINEERING ANALYSIS NEEDED G-Force requirement What will the
helmet need to withstand in order to protect players from
concussions? Durability How many impacts will the padding have to
be reliable for? How many seasons? Test Rig Can we design a test
rig that matches the specifications of standard testing equipment
that is repeatable, and will allow us to test different impact
scenarios? Prototype Cost Approximately how much will a prototype
cost?
Slide 21
OTHER CONSIDERATIONS Moisture Retention Testing Linear
Hexagonal With or without material cover Material response to
temperature change Playing in Texas? Playing in Upstate NY?
Biocompatability Is material cover necessary? Print Speed and Time
If there is a concussion suffered using our padding, should we
replace it?
Slide 22
Week 9 - 12 Update
Slide 23
Expert Advice Rachel Silvestrini-ISE Department Chris Pietrzak-
BRG sports Joe Abraham- Materials Testing Lab Patent Attorney
TEST RIG Design Considerations from Week 6: Accelerometer
inside the helmet, on the base or both? Must be dropped from a
height that will allow 72 in. of free fall. Single rail or twin
wire guided? Is there a way to capture rotational forces on the
head?
Slide 27
WEEK 9 TEST RIG Two Rail vs. Single Rail Guided Pin Release vs.
Mechanical Latch
Slide 28
WEEK 12 DESIGN Two-Wire Guided Aluminum Carriage Bill of
Materials
Slide 29
Addressing Design Considerations from Week 6: Accelerometer
will be placed at the center of gravity in the headform to measure
G- force on head To measure energy that padding absorbs, an
additional accel. can be placed on outside Will allow 72 of free
fall. Is there a way to capture rotational forces on the head?
Expert Advice: Chris Pietrzak (BRG sports)
Slide 30
BILL OF MATERIALS FOR TEST RIG
Slide 31
FINITE ELEMENT ANALYSIS Static Testing Dynamic Testing
Slide 32
Solidworks 3D Scans
Slide 33
Combined Scans
Slide 34
Extra Testing Protocols Cleaning Test Soak Test Durability Test
Customer Survey
Slide 35
Workflow Diagram
Slide 36
Project Planning
Slide 37
RISK ASSESSMENT IDRisk ItemEffectCauseLikelihood Severit y
ImportanceAction to Minimize RiskOwner Describe the risk briefly
What is the effect on any or all of the project deliverables if the
cause actually happens? What are the possible cause(s) of this
risk? L*S What action(s) will you take (and by when) to prevent,
reduce the impact of, or transfer the risk of this occurring? Who
is responsible for following through on mitigation? 1 Is TPU foam
the best option for preventing concussion impacts Wont change our
project. However future MSD projects could be focused on the new
material New types of foam are discovered 313 This concern is
outside the scope of the project. We accept that this is a high
possibility None 2 Cell wall stiffness will affect density
calculations and segment size This will primarily determine how big
our foam segments are Printer capability339 Design around this
parameter Kayla/Tiffany 3 Time requirements to scan, import, and
print must be short to make production practical Slow production
will hinder product adoption Printer speed, material required 326
Reduce material requirement without increasing impact forces to the
head Nate/Tiffany 4Will the design and testing phase require more
material than expected Increased project cost Varied designs to
test 224Use computer modeling to insure the design is viable before
actual testing Kayla/Tiffany
Slide 38
5 How will 3-D printed foam help reduce concussions from
rotational impacts Effectiveness at concussion prevention is
reduced Foam is primarily used for linear impacts. Straps can help
with rotational impacts 33c9 A neck guard while not within the
scope of the project could be helpful in reducing rotational forces
on the neck Nate/Scott 6Printer failureDelayed printing time Human
error or machine malfunction 133 Learn how to properly operate
printer within its parameters Chris 7Printer availabilityDelayed
printing time Other students needing printer time 122 Plan printing
time a week in advance with customer Chris 8Printer printing
sizeLimits printing segment size Defined printer capability
224Design the segment size within printer capability Kayla 9Printer
operability Printer can malfunction and delay printing requirements
Ignorant operation of printer 132 Learn required skills to operate
printer efficiently Chris 10Customer accessibility Required answers
could delay schedule Dennis likes to travel 326 Plan meetings in
advance. Constant email contact with customer Chris 12 High test
rig costs/failure Go over budget building test rig/failure can
delay foam testing Expensive parts/sensors. Improper build
techniques 224 Visit material design lab to witness proper build
techniques Christian 13 Sense software and scanner produce
incomplete scans Extra time reproducing complete scans Limited
capability of Sense hardware and software 111 Expect extra time to
obtain complete and usable head scans/check with Dennis
Nate/Tiffany 14Integrating solidworks and scanning software
Frustration with obtaining custom segment sizes Limited capability
of Talking between softwares 122Check with Dennis/team members
Nate/Tiffany
Slide 39
15 Acceleration sensor accuracy Inaccurate measurements of
impact forces Inefficient placement or lower quality sensor 121
Preliminary testing will show how good a sensor we need Christian
16 Failing to meet project plan deadlines Fall behind schedule and
miss deliverable due dates Related to numerous other concerns and
risks 224 Constant contact with team members. Be willing to ask if
you need help Chris 17 Cracked plastic helmet during testing
Increased cost for extra helmet and delayed testing time Hard
testing impact236 Research previous test plans. Did they have this
problem within test parameters? Scott 18 All printed designs do not
meet requirements spec Unmarketable idea. Maybe printed TPU is
inefficient compared with marketed helmet foams 339 Complete lots
of testing. Exhaust all options Kayla Christian 19Adhesive failing
Inaccurate force measurements. Failed test Adhesive used to apply
foam segments fails 122 Durability issue most likely apparent
during testing. Apply more adhesive Scott 20Material sensitivity to
water/sweat and cleaning solutions Does not meet bio- compatibility
and testing parameters TPU form does not respond well to wet
conditions 122Prior TPU material analysis has shown this is a
non-issue with this foam. However printing could change this Kayla
21Helmet durability Test fails the required parameter Foam is not
durable/helmet breaks during testing 224 Redo design for next test
with high emphasis on durability Scott 22Loss of partsIncreased
budget cost. Delayed project We lose parts for the project
133Materials required to be locked up after use Chris
Slide 40
PROJECT PLAN UPDATE
Slide 41
Slide 42
Complete more testing Create Test Rig Force simulation in
Solidworks Print more padding