Overview
In this project, we designed our own helmet on paper with sketches, and then created it in Fusion 360 as a CAD model. During our design, we looked on current helmet designs and used the information in our research to guide the creation of our helmet. To begin the project, we did video tutorial to learn how to use Fusion 360. We then did our research using sources such as the Snell Foundation, which sets standards for racing helmets and their safety.
After we did our research, we created sketches of the design that we wanted, based on the research we did and models that we looked at online. We then imported these sketches into Fusion 360 and made our model with those as a reference. Then, Alexa, my partner, created decals in an iPad program that are on the sides of the helmet.
Here is how the helmet meets the safety requirements we researched (can also be found in the report):
Our helmet is a full face helmet to provide the necessary protection for a racing helmet. Racing at high speeds involves the chance of a high speed, high impact collision in the event of a sudden crash, so we designed a full face helmet to protect the entire head. One important feature that distinguishes this helmet from a standard bike helmet is the chin bar, which is an immovable part that extends outward to cover the jaw. In our design, we made the chin bar have a solid outer shell with a large surface area, and there is crushable foam behind that to slow any impacts and reduce the force of collision. This is known as a crumple zone. We also made this foam go around the rest of the helmet which helps pad impacts from all sides. We know that this foam helps in collisions due to Newton’s Second Law of Motion which states that force is mass times acceleration. The acceleration is the change in velocity over time, and we are going from a very high speed to low speed in a short period of time (often milliseconds). When we add the foam, it provides a cushion that increases impact time and therefore decreases the acceleration (and force). Because of this, the foam is used to absorb the energy from the impact that the outer shell does not absorb. Without the foam cushion, the hard outer shell would immediately hit the face without any cushion slowing down the impact. This is similar to falling down on concrete versus falling into a foam pit.
Another feature of our helmet is the materials used. As mentioned before, the foam inside the helmet is used as padding for collisions. The foam is fireproof as well, in case of engine fires. Another main material in our design is the hard, outer shell of the helmet. The Snell Foundation, which sets standards for racing helmets, says that it does not have to be a specific material, but there are certain conditions that the outer shell must meet such as high durability and no flammability. Commonly used materials in the creation of the outer shell include types of glass, carbon, kevlar (known for its use in bulletproof vests), and other types of fibers. All of these are weaved together to created the hard, glossy outer shell. Lastly, the visor is made out of lexan, which is known for being used for bulletproof glass.As you can see, with many materials strong enough to resist a bullet, the racing helmet is extremely durable.
Lastly, our helmet has all smooth outer surfaces because we do not want protrusions that could get caught on anything. The Snell Foundation states that anything 7 mm beyond the surface of the helmet must break away easily, so we do not have any decorations or accessories on it.
After we did our research, we created sketches of the design that we wanted, based on the research we did and models that we looked at online. We then imported these sketches into Fusion 360 and made our model with those as a reference. Then, Alexa, my partner, created decals in an iPad program that are on the sides of the helmet.
Here is how the helmet meets the safety requirements we researched (can also be found in the report):
Our helmet is a full face helmet to provide the necessary protection for a racing helmet. Racing at high speeds involves the chance of a high speed, high impact collision in the event of a sudden crash, so we designed a full face helmet to protect the entire head. One important feature that distinguishes this helmet from a standard bike helmet is the chin bar, which is an immovable part that extends outward to cover the jaw. In our design, we made the chin bar have a solid outer shell with a large surface area, and there is crushable foam behind that to slow any impacts and reduce the force of collision. This is known as a crumple zone. We also made this foam go around the rest of the helmet which helps pad impacts from all sides. We know that this foam helps in collisions due to Newton’s Second Law of Motion which states that force is mass times acceleration. The acceleration is the change in velocity over time, and we are going from a very high speed to low speed in a short period of time (often milliseconds). When we add the foam, it provides a cushion that increases impact time and therefore decreases the acceleration (and force). Because of this, the foam is used to absorb the energy from the impact that the outer shell does not absorb. Without the foam cushion, the hard outer shell would immediately hit the face without any cushion slowing down the impact. This is similar to falling down on concrete versus falling into a foam pit.
Another feature of our helmet is the materials used. As mentioned before, the foam inside the helmet is used as padding for collisions. The foam is fireproof as well, in case of engine fires. Another main material in our design is the hard, outer shell of the helmet. The Snell Foundation, which sets standards for racing helmets, says that it does not have to be a specific material, but there are certain conditions that the outer shell must meet such as high durability and no flammability. Commonly used materials in the creation of the outer shell include types of glass, carbon, kevlar (known for its use in bulletproof vests), and other types of fibers. All of these are weaved together to created the hard, glossy outer shell. Lastly, the visor is made out of lexan, which is known for being used for bulletproof glass.As you can see, with many materials strong enough to resist a bullet, the racing helmet is extremely durable.
Lastly, our helmet has all smooth outer surfaces because we do not want protrusions that could get caught on anything. The Snell Foundation states that anything 7 mm beyond the surface of the helmet must break away easily, so we do not have any decorations or accessories on it.
Concepts
Acceleration - change in velocity over time
CAD - computer-aided design (ex. Autodesk Fusion 360)
Crumple Zones - areas of an object designed to crumple and absorb energy of an impact
Drag - air resistance or fluid resistance
Force - mass times acceleration (a force is any interaction that will cause an object to change its velocity)
Friction - force that resists motion when two objects or surfaces come in contact
G force - force acting on a body as a result of the acceleration due to gravity
Inertia - tendency of an object to resist any change in velocity
Newton's Second Law of Motion - The acceleration of an object as produced by a force is directly proportional to the magnitude of the force and inversely proportional to the object's mass
Concepts in this project also came from other disciplines, particularly art and design. Once we had determined the safety features, additional parts of the helmet, such as decals, became aesthetic factors that we could decide. CAD is also a large part of design in engineering and other design disciplines.
CAD - computer-aided design (ex. Autodesk Fusion 360)
Crumple Zones - areas of an object designed to crumple and absorb energy of an impact
Drag - air resistance or fluid resistance
Force - mass times acceleration (a force is any interaction that will cause an object to change its velocity)
Friction - force that resists motion when two objects or surfaces come in contact
G force - force acting on a body as a result of the acceleration due to gravity
Inertia - tendency of an object to resist any change in velocity
Newton's Second Law of Motion - The acceleration of an object as produced by a force is directly proportional to the magnitude of the force and inversely proportional to the object's mass
Concepts in this project also came from other disciplines, particularly art and design. Once we had determined the safety features, additional parts of the helmet, such as decals, became aesthetic factors that we could decide. CAD is also a large part of design in engineering and other design disciplines.
Reflection
I had done CAD design many times before, for robotics and other classes, but most of the things I have created have been straight geometries instead of curves and sculpted objects like the helmet. One peak was this exposure to a new facet of CAD for me, because I will now be able to design a larger array of objects. One pit, or something that could've been better, was the timeframe for this project. We finished it very late because it was difficult to juggle this and our capstone project at the same time. I think next time, we need to work more outside of class to get the project done faster.
Another peak was our communication. My partner, Alexa, and I were able to split up tasks and work on things that we were better at. For example, I did more of the CAD design, and Alexa did more of the art decal design. Lastly, another pit was our research. I think we needed more research in the actual materials used for the helmets. We had lots of information on the safety requirements, but we needed more about what the helmets are made of.
Another peak was our communication. My partner, Alexa, and I were able to split up tasks and work on things that we were better at. For example, I did more of the CAD design, and Alexa did more of the art decal design. Lastly, another pit was our research. I think we needed more research in the actual materials used for the helmets. We had lots of information on the safety requirements, but we needed more about what the helmets are made of.