P 15550 Customized Personal Protection Headwear Preliminary DDR

P 15550: Customized Personal Protection Headwear Preliminary DDR Team Leader: Chris Casella Nate Marshall Tiffany Gundler Scott Quenville Christian Blank Kayla Wheeler

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

PROBLEM STATEMENT Current State: ● Limited to manufactured helmets in contact sports Desired State: ● Custom Fit helmets using 3 D 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 3 D printed cellular materials ● Semi-automated workflow for sending scanned dimensions to Solid. Works to the 3 D printer ● 3 D printed, customized, energy absorbent pads ● Custom fitted football helmet with pads ● Drop test rig with impact sensor feedback

BACKGROUND

BACKGROUND ● ● 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 29 th, 2013 a lawsuit was taken against the NFL for a total of 765 million dollars. Manufacturers Include: Riddell, Schutt, Rawlings, and Xenith.

CURRENT PRODUCT- Schutt ION 4 D 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 X 1

STAKEHOLDERS Denis Cormier Athlete Trainer Medic Manufacturer Hospital Insurance?

Problem Definition

CUSTOMER NEEDS Key: 9 -Very Important 3 - Important 1 - SImportantomewhat

ENGINEERING SPECIFICATIONS Key: 9 -Very Important 3 - Important 1 - Somewhat Important

BENCHMARKING SPECS A - instantaneous acceleration

SYSTEM ANALYSIS

HOUSE OF QUALITY Key: ϴ- Strong Correlation O- Moderate Correlation - Weak Correlation

FUNCTIONAL DECOMPOSITION 2141 MSD 1 13026 annotated System Level Design Review Presentation

Systems Design

ALTERNATIVES CONSIDERED

ALTERNATIVES CONSIDERED (PUGH EVALUATION CHART)

ALTERNATIVES CONSIDERED

SYSTEM ARCHITECTURE

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

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?

Week 9 - 12 Update

Expert Advice ● Rachel Silvestrini-ISE Department ● Chris Pietrzak- BRG sports ● Joe Abraham- Materials Testing Lab ● Patent Attorney

Test Plan Expert Advice: Rachel Silvestrini (ISE)

Compression Test Results Expert Advice: Joe Abraham (Materials Testing Lab) Sample Schutt Block 1 Block 2 Block 3 Block 4 Block 5 Block 6 Block 7 Block 8 Peak Force (lbs) 504. 1 41. 1 86. 0 132. 2 173. 2 26. 4 120. 4 266. 0 457. 1 Deflection (inches) 0. 40 0. 11 0. 19 0. 11 0. 18 0. 19 PSI 298. 1 10. 27 21. 5 33. 05 43. 3 6. 6 30. 1 66. 5 114. 28 Block 1: 5% Ninjaflex Block 2: 15% Ninjaflex Block 3: 30% Ninjaflex Block 4: 45% Ninjaflex Block 5: 5% Filaflex Block 6: 15% Filaflex Block 7: 30% Filaflex Block 8: 45% Filaflex

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?

WEEK 9 TEST RIG ● Two Rail vs. Single Rail Guided ● Pin Release vs. Mechanical Latch

WEEK 12 DESIGN ● Two-Wire Guided ● Aluminum Carriage ● Bill of Materials

Addressing Design Considerations from Week 6: ● Accelerometer will be placed at the center of gravity in the headform to measure Gforce 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)

BILL OF MATERIALS FOR TEST RIG

FINITE ELEMENT ANALYSIS ● Static Testing ● Dynamic Testing

Solidworks 3 D Scans

Combined Scans

Extra Testing Protocols ● ● Cleaning Test Soak Test Durability Test Customer Survey

Workflow Diagram

Project Planning

RISK ASSESSMENT ID Risk Item Effect Cause Likelihood Severity Importance Action to Minimize Risk Owner 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 Won’t change our project. However future MSD projects could be focused on the new material New types of foam are discovered 3 1 3 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 capability 3 3 9 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 3 2 6 Reduce material requirement without increasing impact force’s to the head Nate/Tiffany 4 Will the design and testing phase require more material than expected Increased project cost Varied designs to test 2 2 4 Use computer modeling to insure the design is viable before actual testing Kayla/Tiffany

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 3 3 c 9 A neck guard while not within the scope of the project could be helpful in reducing rotational forces on the neck Nate/Scott 6 Printer failure Delayed printing time Human error or machine malfunction 1 3 3 Learn how to properly operate printer within its parameters Chris 7 Printer availability Delayed printing time Other students needing printer time 1 2 2 Plan printing time a week in advance with customer Chris 8 Printer printing size 2 4 1 3 2 Design the segment size within printer capability Learn required skills to operate printer efficiently Kayla Printer operability Defined printer capability Ignorant operation of printer 2 9 Limits printing segment size Printer can malfunction and delay printing requirements 10 Customer accessibility Required answers could delay schedule Dennis likes to travel 3 2 6 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 2 2 4 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 1 1 1 Expect extra time to obtain complete and usable head scans/check with Dennis Nate/Tiffany 14 Integrating solidworks and scanning software Frustration with obtaining custom segment sizes Limited capability of “Talking” between software’s 1 2 2 Check with Dennis/team members Nate/Tiffany Chris

15 Acceleration sensor accuracy Inaccurate measurements of impact forces Inefficient placement or lower quality sensor 1 2 1 Preliminary testing will show 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 2 2 4 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 impact 2 3 6 Research previous test plans. Did they have this problem within test parameters? Scott 18 All printed designs do not Unmarketable idea. meet requirements spec Maybe printed TPU is inefficient compared with marketed helmet foams 3 3 9 Complete lots of testing. Exhaust all options 19 Adhesive failing Inaccurate force measurements. Failed test Adhesive used to apply foam segments fails 1 2 2 Durability issue most likely apparent during testing. Apply more adhesive Scott 20 Material sensitivity to water/sweat and cleaning solutions Does not meet biocompatibility and testing parameters TPU form does not respond well to wet conditions 1 2 2 Prior TPU material analysis has shown this is a non-issue with this foam. However printing could change this Kayla 21 Helmet durability Test fails the required parameter Foam is not durable/helmet breaks during testing 2 2 4 Redo design for next test with high emphasis on durability Scott 22 Loss of parts Increased budget cost. Delayed project We lose parts for the project 1 3 3 Materials required to be locked up after use Chris Kayla Christian

PROJECT PLAN UPDATE

PROJECT PLAN UPDATE

PROJECT PLAN UPDATE ● ● Complete more testing Create Test Rig Force simulation in Solidworks Print more padding

QUESTIONS