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COMPETENCE IN TEXTILES
Using 3D Scanning
for Improved Helmet Design
Dr. Jan Beringer │ Hohenstein Institute
Hohenstein Webinar │ June 17th, 2015
No. 2
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Introduction
Increasing number of users
• Growing markets in job, leisure and sports
• From children to seniors
• Skiing: 16 million skiers in GERmany
• Biking: 68 million bikes in GER, not all bikers wear helmets
• Industry: 10 million workers in GER with need for head protection
• Furthermore: Forest operation, fire dept, police, military, inline
skating, rock climbing, horse riding, motorcycling, canoeing and
rafting …
• Growing safety demands by awareness
both legal regulation and voluntary motivation
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Introduction
The Facts / Findings
• Helmets avoid or reduce the risk of head injuries
• 2011: 79.000 notifiable accidents at work with head injuries were
(according to German statutory accident insurance)
• Head injuries often lead to secondary damage like paralysis and /
or speech disorder
• Economic benefit: Reduction of insurance expenses, patient care
and rehabilitation
• Consumer acceptance is needed
Only wearing a helmet can prevent from severe head injuries !
• Fit (and wearing comfort) optimized helmets are needed !
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Introduction
The Challenge
• “SizeGERMANY” sizing survey showed remarkable variations in
head shapes within the same head circumference
• Additional high-resolution anthropometric head data is needed,
in particular shape information
• Market shares in head shape are needed for best market coverage
• Industry standards do not comply with the state of technology
anymore, head shape information is missing totally
• Influence of hair on the size measurements and helmet fit is unclear
Important basic information for optimized helmet
development is not available
Person 2
Person 1
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front
back
Circum-
ference
58 cm
back
front
Visual comparison – male subject (view from top)
male 1
male 2
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State of technology
Worldwide head-sizing related activities:
• CAESAR-project, 1997-2001 (NL/US)
• NIOSH Anthropometric Survey of Respirator Users, 2001-2004 (US)
• SizeChina (2006): Anthropometric head survey and digital database of
Asian heads and faces for use by manufacturers (about 1600 Scans)
• 3D Facial Norms Database (https://www.facebase.org)
3500 healthy Caucasian individuals age 5-40 (US)
• Various papers (US & CAN):
- Head-and-face shape variations of U.S. civilian workers (2013)
- A simple and standardized method for analyzing head and face
morphology of a population sample (2010)
- Sizing trials of a prototype aircrew helmet (2009)
- Principles of Fit to Optimize Helmet Sizing (2006)
- Helmet accommodation analysis using 3D laser scanning (2000) etc.
Head shape comparison - Size China
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Aim of the Hohenstein study
Results:
• Up-to-date face and 3D head measurements and head
shapes of men, women and children in Germany
• German market share tables of sex, age and head shape types
• Head specific grading guidelines
• Virtual 3D-head shape models
• Guidelines and design characteristics for optimized
development considering fit, ergonomic comfort,
thermophysiological comfort and hygiene
The Aim is the improvement of head gear systems
considering fitting plus comfort and function
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• Detailed analysis of existing 3D Scan data of
Hohenstein’s own database (17,000+ scans)
• Acquisition of additional high resolution
3D Scan data from typical head shapes
• Definition of measurements and methods
according to established standards like (ISO
7250, SizeGERMANY etc. plus new
additional head and face measurements)
Step 1 of the Hohenstein study and results
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Available 3D Scanner Systems
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3D Scan-Quality
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3D Scan experimental setup
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• Analysis und statistical evaluation of
3D-scandata of men, women and children
• 3D-head shape analysis
• Definition of basic 3D head shapes
• Definition of size ranges
according to sex, age
and head shape types based
on percentage shares
Step 2 of the Hohenstein study and results
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Men & Women:
Head circumference - percental distribution
0%
5%
10%
15%
20%
25%
30%
52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Kopfumfang [cm]
Kopfumfang: Prozentuale Anteile - Männer und Frauen
Männer
Frauen
0,03%0,16%
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Boys: Head circumference over age groups
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Girls: Head circumference over age groups
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Men & Women: Rage of head width
(correlation head width vs. head circumference)
Korrelation Kopfbreite zu Kopfumfang
14,0
15,0
16,0
17,0
18,0
19,0
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Kopfumfang [cm]
Ko
pfb
reit
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cm
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FrauenMänner
MAX
MIN
Mittlere Spannweite 2,5 cm
Gr.58 = 3,4 cm Spannweite
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Men & Women: Definition of head shapes and types
(correlation head width vs. head circumference)
Korrelation Kopfbreite zur Kopfumfang
13,5
14,0
14,5
15,0
15,5
16,0
16,5
17,0
17,5
18,0
18,5
19,0
52 53 54 55 56 57 58 59 60 61 62 63 64
Kopfumfang [cm]
Ko
pfb
reit
e [
cm
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rund
oval
normal
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The 5 defined/extracted average head types
normal oval oval extremrundrund extrem
+ 0,8cm +0,8cm +0,8cm + 0,8cm
+ 0,4cm + 0,4cm + 0,4cm + 0,4cm
X round round normal oval X oval
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Men: percental distribution head types
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Women: percental distribution head types
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Head height types (…helmet belt)
Definition of 5 head hight types
normalX short short long X long+ 2 cm + 2 cm + 2 cm + 2 cm
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Average head shapes as 3D data available
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• 3D Scan system and experimental setup defined
• 3D-scandata of men, women and children analyzed and
statistically evaluated
• 3D-head shapes analyzed and 5 basic types defined
• Size ranges according to sex, age and head shape types
based on percentage shares defined
• Average head shapes in various sizes available as 3D data
Summary
No. 24
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Thank you for your kind attention
Hohenstein Institute America, Inc.
Samuel B. Moore, Ph.D & Ben Mead
1688 Westbrook Ave | Burlington, NC 27215 | USA
[email protected] | b.mead @hohenstein.com
www.hohenstein.us
Hohenstein Institute
Dr. Jan Beringer & Simone Morlock
Schloss Hohenstein | 74357 Boennigheim | GERMANY
