P15550: Customized Personal Protection Headwear

Build, Test, Document

Table of Contents

During weeks 1 and 2 of MSD II we worked on updating our test plan, project plan and risk management document. We are currently utilizing the problem tracking template to keep track of current issues with the project. A new bill of materials was created for additional materials needed for the project. After the week 2 review, new parts to were ordered for the printer.

Week 3-5 Summary

For the past 3 weeks we have been working on SolidWorks simulations to determine the energy absorption of various densities of padding. We are currently summarizing this data to determine what density or densities will provide the most protection to the athlete. Also, we have modeled the entire padding insert in SolidWorks that will get printed and inserted into our helmet. Work is also being conducted on the merging the helmet and head scan together in solid works. The test rig base plate has been water-jetted and assembly has begun on the test rig. An updated project plan, problem tracking and risk assessment has been updated and posted on edge.

Goals for Week 8:

1. Finish test rig assembly

2. Perform drop tests and collect data using Linx IAS technology

3. Troubleshoot any test rig issues

4. Complete 75% of Final Paper

5. Complete helmet/head scan merging

Week 5-8 Summary:

The simulation results have been analyzed and summarized in a test report document to finalize our ideal material density. We have completed the head scan process by merging the solid head form with the helmet and determining the dimensions of both for the final padding designs. The base plate water jet process was completed and the test rig base is completely assembled. The designs for the protective padding inserts are also complete, but may change slightly depending on printer capabilities.

We are currently in the process of printing out our padding design in different parts and also putting together the final paper summarizing the entire senior design process. We also are working on completing the test rig assembly process. By the next review we plan on having the paper complete except for the final results section, the padding inserts printed out and the test rig completely assembled so we can begin our next phase of testing our product.

Week 8-11 Summary:

All of the padding has been printed and attached to the helmet with Velcro. The final construction of the test rig has also been completed. We have attached a pulley system with a rope to aid us with lifting the head form assembly and dropping the helmet from the desired height. We met with Dr. Borkholder and he has lent us 2 Linx IAS sensors, which use Bluetooth to communicate with an iPad to give us our force impact data. A sweat test was also performed by placing a piece of our padding into a saline solution to test how long term usage of the material would be affected by continuous sweating. The results were successful in that the padding retained its original color and shape and density. We have completed 75% of the final paper and will be finished upon completion of the testing phase. Looking ahead, we will use the test rig to generate the necessary data for the project. Additional test will also be run in order to meet all of the customer requirements. Final additions to the workflow and paper will made before Imagine RIT. By mid May, the project will be completed. A final demonstration and presentation will be used to conclude the MSD II experience.

Week 11-14 Summary:

During Weeks 11 through 14, we prepared our project for the Imagine RIT festival. We also successfully implemented the Linx IAS sensors into our drop test rig to collect data. Our final paper was reviewed by other MSD students and the appropriate edits were made. Finally, our team completed our durability, cleaning and soak tests on the padding.

Within the next few weeks, we will have completed our final project demo/presentation and gate review. Edge will be completely updated with the Performance and Requirement Document, Risk Assessment and Project Plan.

Week 15 Summary:

During Week 15 we conducted our final demo/presentation required for MSD II. We also we with our guide for the final time during our Gate Review. We finished updating all of the necessary documents and uploaded them to edge. Finally, our team cleaned up our work space and handed off the custom fit helmet to our customer.

After the completion of testing, we have concluded that our 3D printed padding produces very similar energy absorption to the manufacturer’s padding. Our average impact severity was 0.6 units, or 0.7%, higher than the competitor’s. However, considering our limited budget and timeframe, it has been a successful project.

MSD II Project Plan

The most up to date project plan available can be found here: Project Plan

Total Project Cost

The total project cost up to week 11 for MSD II can be found here: Project Expenses

Build, Test, and Integrate

The previous test rig design has been discarded as new requirements were presented to us from our customer. The new test rig design can be seen here: Test Rig Design

As a result of the new test rig design, more materials had to be ordered as well as a second helmet and attachments. The updated bill of materials can be found here: Complete BOM

Pictures of the building process of the test rig were documented to show how we designed certain aspects. The pictures can be seen here: Test Rig Progress

Risk Management

The risk assessment has been modified to account for issues we encountered toward the end of MSD I and issues that we could possibly encounter in MSD II. The most updated risk assessment can be found here: Risk Assessment

A problem tracking sheet has been created to help us track and rate the problems as they get resolved or as they continue to be an issue. This tracking sheet can be seen here: Problem Rating and Tracking

Test Plans & Test Results

The test plan consists of 4 tests that can be found in the 'System Level Build, Test & Documentation' node of MSDII. The current test plan template for MSD II can be found here : Current Test Plan

We have created a document that highlights all of the engineering requirements that we started with and we went through to rate which ones we accomplished and which ones we did not. This document can be found here: Performance vs. Requirements

Our test results of the impact forces we measured for both our padding and the competitors padding during the drop testing phase can be found here: Test Rig Data

Assembly Instructions

The assembly document for building the test rig can be found here: Test Rig Assembly

Semi-Automated Workflow Document

The Workflow document can be found here: Workflow Procedure

This is a key document to help understand the process of creating a customized head form. It incorporates the initial write-up for the settings and actions needed to 3-D print our designs.

Meetings and Weekly Deliverables

Meeting with Dr. Cormier 1/29/15

1. Try drilling out nozzle with 1/2 mm drill bit or reamer

2. Try replacing the nozzle (not brass)

3. Purge every trial with PLA after each run

4. Try running solvents for Ninjaflex and Filaflex materials to clean out the nozzle

5. Order new nozzle that works better with our materials

Week 3 Update Notes:

We have created a document that shows where we where at the end of MSD I and where we are now in MSD II as long as our plan for the rest of the semester. This document has been attached here: Week 3 Updates

Week 5 Review:

We successfully completed our Week 5 review. We discussed the current status of the Drop Test Rig, Solid Works 3D padding insert for the helmet, Solid Works dynamic simulation results and our progress on merging the helmet and head scans.

Week 8 Review:

We successfully completed our Week 8 review. We finished the assembling all aspects of the test rig. We discussed the current state of the poster and continued printing out the padding for the helmet.

Week 11 Review:

We successfully completed the our Week 11 review. We finished printing the padding for the helmet and performed our soak test on the padding. We made progress on designing the poster and began attaching the padding to the helmet.

Week 15 Review:

The Final Gate Review and the final MSD presentation can both be found in the publications node.

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