HexGen

What it does

HexGen is a custom-made helmet that uses generative design to create a lightweight, comfortable liner with advanced impact absorption The 3D printed liner is created unique for each user and also responds to specific impact parameters.

Your inspiration

The whole project started with my fascination and experimentation with generative design. Generative design is a computer process that uses algorithms and artificial intelligence to create optimal and lightweight shapes that we as humans would normally not be able to create easily. After getting acquainted with generative design, doing immense research, and taking into account my love for skiing, I decided to design a custom ski helmet.

How it works

The helmet is made from three layers: outer shell, custom-made 3D printed liner and soft padding. The outer shell is made by vacuum forming the polycarbonate sheet and it comes in universal sizes. It protects the users from piercing impacts, and it spreads impact energy across the whole head. The inner layer is custom-made to fit between the 3D scan of the user's head and outer shell. Each head is unique. And for the helmet to work best it is important that helmet fits perfectly. That inner layer is made out of lattice cells that have different beam thickness, that way structure is good for high energy impact and low energy impacts. Another advantage of lattices is that they spread impact energy easily and can sustain both rotational and linear impacts. It is printed from TPU, and printed structure makes it easy for air to flow through it, ensuring enough cooling of the head. The last layer is padding for extra comfort, made with dry-fit fabric.

Design process

To create the "HexGen" I started with developing an algorithm that will generate the optimal shape using four different parameters. The first parameter is getting the 3D scan of the head. Nowadays it is quite accessible and it is possible to get a good quality scan just by using your smartphone. After that, I was collecting on-field data from my various ski trips. I was monitoring speed and calculating which energy the structure needs to absorb. The third parameter is about researching most vulnerable spots in the brain, that way algorithm will create denser structure at those points for more safety, and it can save on material in other areas to create lighter structure. The last parameter is giving the algorithm all the possible lattice shapes it can use. After inputting all the parameters, the algorithm will create and simulate hundreds of different shapes, varying the lattice shape, size and beam thickness. I chose the one that performed best. The generated structure is separated into ten pieces so that it can be printed on multiple printers in less time and with less support. Printed pieces are welded together using heat and connected with the outer shell, earpads and straps with a snap-fit joint.

How it is different

A typical helmet uses expanded polystyrene foams that are rigid, come in standard sizing and change their properties in different weather conditions. Polystyrene is good as an insulator, but not as a shock absorbing material. It will harden on impact and become unusable. HexGen is made out of TPU, which has better shock absorption and is consistent in every weather. Because of the lattice structure, it allows air to circulate and help the body cool itself. Lattices provide advanced shock absorption. The TPU has an elongation of 600%, thus it can be hit multiple times and still keep all the attributes. Besides that, it is custom made for each athlete. No two heads are the same. Each helmet is different to grant maximum comfort and protection. Compared to the usual helmets, HexGen is more sustainable. Overall lifetime of the product is increased, therefore producing less waste, and it can be easily disassembled and recycled, there is no glue to stain parts.

Future plans

The next step would be making the smartphone application, which can be used for generating custom ski helmets. It will be used by the potential customers for creating 3D head scans and for customizing and purchasing the helmets. Also, I would apply the same lattice structures in other fields. The biggest advantage of HexGen is that the same algorithm can be used for generating structures for various protective equipment, not just helmets. I hope to develop a new type of universal sustainable protective structures, that can be applied for different sports using advanced materials.

Awards

BCV Award- the prize awarded to a graduate student in Master Product Design who has distinguished himself by the overall quality of his work