Design and Development of Composite

Helmet to Resist High Velocity Impact

Basit Ali 070

Haider Ali 074
Final Year Project Supervisor
Usman Arif 058
Mr. Muhammad
Hussain Ali Khan
Azeem
061
 Presentation Outline
Title 01

Problem Statement 02

Aim and Objective 03

Introduction 04

Statistical Analysis 05

Literature Review 06

Methodology 07

Project Completion Timeline 08

Reference Slide 09
 Problem Statement

According to reports of Road Traffic accident fatalities due to head injury in motorcycle
accidents in 2019 and 2020 in Karachi Pakistan [1] , the fatalities due to head injuries
in bike accident is 53 %. In our surrounding the fatalities rate and head injury in
incident are increase day by day due to limited safety of plastic helmets This problem
address the critical need for an economical and low-cost alternative. Our project is to
design and develop a composite helmet that is combined cost-effective materials with
high-impact resistance, that is sustainable and safer solution for head protection.
Aims

01 To make helmet that is light weight

and bears high velocity impact.

02 More durable than a conventional

helmet.

03 Provides more safety

04 Economical than conventional

helmets

4
Objectives
Objectives
Manufacturing of Composite
01
Helmet using hand layup technique
and 3D printing method.

Compare with Conventional Plastic

02 Helmet.

03 Simulation Using Ansys/ABAQAS.

 Introduction
A helmet is a safety equipment that is used to provide protection to the
head. The main purpose of helmet is to absorb and dissipate the force of
impact, that results in injury reduction. Helmets are commonly used in
varieties of activities or industries

Construction
Motorcycle Helmet Military Helmet
Helmet Bicycle Helmet
 Types of Motorcycle Helmet

Modular Helmet Off Road Helmet Full Face Helmet Half Helmet
Classification of helmet on the basis of velocity impacts

01 02 03

Low Velocity High Velocity Hyper Velocity

Impact Impact Impact
Velocity Range from 0 m/s Velocity Range from 10 m/s Velocity Range from above
to 10 m/s to 100 m/s 100m/s

8
 Statistical Data
According to reports of Road Traffic accident fatalities due to head injury in
motorcycle accidents in 2019 and 2020 in Karachi Pakistan [2].

Anatomical Cause Of Death Percentage Of Injuries

9
 Literature Review
Author (year) Standard Material Testing type Parameter Title

Megan l Band, Craig STAR testing Impact Velocity Star Methodology for
Steel Oblique impact testing
Mcnally [3] (2018) /methodology (4.8 m/s – 7.3 m/s) Bicycle Helmets

Azhar hamza, Iqbal Comparative Study of

Impact Velocity
Hafeez [4] MSI:1996 Protocol ABS Drop test technique Motorcycle Helmet
(5.9 m/s)
(2014) Impact Performance

Effectiveness Of Wearing a
Yasuhiro Matsui, Shoko
Bicycle Helmet for Impact
Oikawa & Naruyuki Finite element models Impact Velocity
FIGO G-1 Soft polyurethane Against the Front of A
Hosokawa [5] analysis (Ansys) (9.7 m/s)
Vehicle And The Road
(2018)
Surface

Acrylonitrile butadiene
Intikhab khan
styrene (ABS), Finite Element Analysis on
Aditya shinde Finite element analysis Impact Force
FIS, FMVSS Polycarbonate with 30% Different Materials for
Shresth Khandelwal [6] (ABAQAS) (19.5 KN)
glass, Motorcycle Helmet
(2019)
Epoxy glass fiber

Varun Agarwal Design and analysis of the

Finite element analysis Impact Velocity
Jivya Jain [7] FMVSS Steel motorcycle helmet using
(Ansys) (5.2 m/s)
2018 FEA analysis.

10
 Literature Review
Differences in the protective
Shell Material Polycarbonate
Megan L. Bland, David S. capabilities of bicycle
(PC) or Acrylonitrile
Zuby, Becky C. Mueller & Consumer Product Safety Drop Test and Impact Test Impact Velocity helmets in real-world and
Butadiene styrene (ABS)
Steven Rowson [8] Commission (CPSC) (3.4m/s and 6.2m/s) standard-specified impact
Inner Liner Expanded
27 March, 2018 scenarios.
Polystyrene (EPS)

Consumer Product Safety

Outer shell: ABS plastic
Commission (CPSC),
Inner Liner: Expanded
Javid Abderezaei1, Fargol Australian and New Zealand An Overview of the
Polystyrene (EPS) or
Rezayaraghi1, Brigit Kain2, Standard (AS/NZS 2063), EN Effectiveness of Bicycle
Expanded Polypropylene Impact test and Drop Test Impact Velocity
Andrea Menichetti3 and 1078, Snell Memorial Helmet Designs in Impact
(EPP) (3.4m/s to 7.4m/s)
Mehmet Kurt. [9] Foundation (e.g.B95) and Testing.
Inner Shell: Soft Foam
27 September, 2021 American Society for Testing
Padding
and Materials (ASTM F1447)

Arnaldo Jacob, Caroline Acrylonitrile Butadiene

Impact Speed for
Faria, Gustavo Cardoso, styrene (ABS) for Bike Evaluation of Helmet
Impact Test Motorcycle Helmet
Klebson Reis, Mariana High Density Polyethylene Protection during Impact of
Finite Element Analysis on (20 m/s and 25 m/s)
Motta, Thiago Meneghetti, (HDPE) for Construction Head to Ground and Impact
ABAQUS Impact speed for Bike
Roberto Cammino*, Aiman Carbon Fiber and Kevlar for of an Object to Head Using
Helmet
Shibli [10] Motorcycle Finite Element Analysis.
(7 m/s and 8.5 m/s)
5 May, 2016

11
 Literature Review
FADY ABAYAZID, KE A New Assessment of
DING, KARL Bicycle Helmets: The
Drop Test
ZIMMERMAN, HELENA Aluminum Casting or Impact velocity Brain Injury Mitigation
FEA Analysis
STIGSON, and MAZDAK PVC Skin (6.3 m/s) Effects of New
Oblique impact testing
GHAJARI [11] Technologies in Oblique
24 April,2021 Impacts

Irfan Sadaq Shaik, Md.

Acrylonitrile Butadiene Finite element analysis Impact Test on
Abdul Raheem Junaidi,
Styrene Abs, (COSMOS software) Impact Velocity Motorcycle Helmet for
Joseph George Konnully
Polyvinyl Chloride PVC and impact analysis (13.9 m/s – 19.4 m/s) Different Impact angles
[12]
using FEA.
July, 2014

Impact analysis of a
Shunfeng Li, Zhi Xiao,
honeycomb-filled
Yunfei Zhang, Q.M. Li ABS Shell Impact Velocity
Standard ECE R22.05 Drop Test motorcycle helmet based
[13] EPS Foam (7.5 m/s)
on coupled head-helmet
2021
modelling.

Arnav Gupta1, Dr. Acrylonitrile butadiene Finite Element Analysis

Impact Velocities
Mohammad Mursaleen styrene (ABS) or plastic, FEA Analysis using of the Motorcycle
(8.3 m/s and11 m/s)
[14] Ansys software Helmet Material against
September, 2021 GFRP Polycarbonate Impact Velocity.

12
 Literature Review
IMPACT TEST ANALYSIS
ON A 2-WHEELER
Saroj Kumar Biswal,
The British, American HELMET USING 3D
S.M.Shahrukh Rais, FEA Analysis using Impact Velocity
standards as well as the ABS and PVC MODELLING AND
Karanam Krishna [15] Ansys software (13.9 m/s -19.4 m/s)
IS ANALYSING SOFTWARE
April, 2016
FOR TWO DIFFERENT
MATERIALS

Acrylonitrile butadiene
Kirk Hansena, Nathan BSI, 1997 styrene (ABS) outer Angular Impact
Daua, Florian Feist, shell, Expanded Oblique Impact Test or Mitigation system
Caroline Deckc, Rémy Consumer Product polystyrene foam (EPS) Normal Impact Test for bicycle helmets to
Impact velocity
Willinger, Steven M. Safety Commission liner, Inner layer of reduce head
Computational analysis (4.8 ± 0.0 m/s)
Madeya, Michael CPSC, 1998 polyurethane comfort acceleration and risk of
Bottlanga, [16] foam padding of Control using SUFEHM traumatic brain injury.
16 May, 2013 helmet.

British Standard BS 6863

was replaced by EN
N.J. Mills-, A. Gilchrist 1078. Impact Velocity < 5.42
Aluminum Casting or Oblique Impact test m/s Oblique impact testing
[17] EN 1078 (The dates of PVC of bicycle helmets
10 August 2007 manufacture were
between August 2004
and March 2005)

13
 Motorbike protective helmets,
Impact velocity construction, testing and its
Maciej OBST1 , Szymon
AS/NZS Aluminum Impact Test 0.9m/s to influence on the type and severity of
RZEPCZYK3, (2023)
10.5m/s injury of motorbike accident
causalities

High impact
B. Vaishnavi, Perumalla Divya Sri, polystyrene(HIP)
Study on two wheeler helmet for
Thigulla Harsha Vardhan, Thermoplastic FEA Analysis on Impact force
- reducing head injury on different 3D
Anshuman Kumar , 11 October Elastomer (TPE) ANSYS 19.5kN
printed material
2023 polypropylene(PP
)

printed poly-
lactic acid (PLA)
Ammar Mustafa Al‑Areqi1 lattice frame in Development of 3D Printed
Tensile,compressi
· Bandar Aloyaydi1,2 · filled with Biodegradable Poly‑lactic Acid/
Universal testing on and three-
Subbarayan Sivasankaran1,2 · ASTMD790 polyurethane Polyurethane Foams/Milled Glass
machine point bending
Fahad A. Al‑Mufadi1,2 foams (PUFs) Fibers of Sustainable Composites
test
(2022) reinforced with with Application on Helmet
milled glass
fibers(MGFs)
Methodology 0 Literature Review for the
1 manufacturing of
composite helmet

02 Simulation of the
helmet using Abaqus

0 Manufacturing of
3 helmet by using 3D
printing and hand
layup method
0 Drop weight Testing
4 using pendulum
weight impact testing

15
 Drop
Drop Test Headform Impact No of Failure
Standard Year Head form Assembly Anvils
Apparatus Sizes Criteria Impacts Criteria
Weight
< 400g
Small 3.5 kg Velocity: Two at 2.0 ms at
FMVSS Flat
1988 Monorail DOT Medium 5.0 kg 6.0 m/s each of 4 200g
NO. 218 Hemi
Large 6.1 kg 5.2 m/s sites 4.0 ms at
150g
Velocity:
Small Flat & Two at
ANSI Monorail or Flat
1992 DOT or ISO Medium 5.0 kg hemi each of 4 ≤ 300g
Z90.1 Guide Wire Hemi
Large 6.9 m/s sites
6.0 m/s
≤ 300g
Small 3.5 kg Drop
Magnesium Two at 3.0 ms at
Medium 4.0 kg Flat Height
AS 1698 1988 Guided Fall AS 2512.1 each of 4 200g
Large 5.0 kg Hemi 1830 mm
(DOT) sites 6.0 ms at
6.0 kg 1385 mm
150g
Velocity:
7.5 m/s
Type A 5.3 m/s
Flat 7.0 m/s Two (same
Small
Hemi 5.0 m/s anvil) at
BS 6658 1985 Guided Fall ISO Medium 5.0 kg ≤ 300g
Type B each of 3
Large
Flat 6.5 m/s sites
Hemi 4.6 m/s
6,0 m/s
4.3 m/s
 Low
Small 5.1 m/s Energy:
Two at
CAN3- Medium Flat 7.2 m/s ≤ 200g
1985 Guided Fall ISO 5.0kg each of 4
D230 Large Hemi 4.3 m/s High
sites
XL 6.1 m/s Energy:
≤ 300g

Flat &
Energy:
Hemi:
Flat &
Small Two each
Flat Hemi
Monorail or Medium ≥ 5.0 kg at 4 sites
Snell M-95 1995 ISO Hemi 1501 ≤ 300g
Guide Wire Large ≤ 6.5 kg Edge:
Edge 1101
XL One
Edge
impact at
1501
one site

4 site per
3.1 kg helmet in
Unrestrained Small Velocity Resultant
4.1 kg sequence
Head form with Medium Flat 7.5 m/s ≤ 275g
ECE 22.4 1995 ISO 4.7 kg with 5th
Tri-axial Large Curb for both HIC ≤
5.6 kg test at 4
Accelerometer anvils 2400
6.0 kg m/s and
8.5 m/s
Dot Standard
Impact Attenuation:
• Measure energy absorption during impact.
• Impact test involves dropping a headform from a fixed height onto a
spherical and flat surfaced anvil.
• Acceptable peak acceleration energy: 400G.
Penetration Resistance:
• Involves dropping a piercing test striker onto the helmet from a fixed
height.
• Striker must not penetrate deep enough to contact the headform.
Retention System Effectiveness:
• Tests the effectiveness of the helmet's retention system (straps).
Progressive load test:
• 22.7 kg (49.9 lb.) applied for 30 seconds.
• Increased to 136 kg (299.2 lb.) for 120 seconds.
• Measures stretch or displacement of a fixed point on the retention strap
from the apex of the helmet.
 Material PLA ,Glass Fiber

Standard DOT

Testing type Impact testing ,Drop weight .

velocity 6 m/s to 12 m/s

Parameters Velocity & force

Anvil type Hemi-spherical

Technique 3D-Printing & Hand layout

Drop weight 3.5 to 4 kg

Nominal Fall 1.38 m

Standard Dot (FMVSS 218)
Anvils
S – 63 J/63 J
M – 90 J/90 J
Flat Anvil
L – 110 J/110 J
Nominal Fall 1.83m
S – 47.3 J/47.3 J
M – 67.6 J/67.6 J
Hemispherical Anvil
L – 82.5 J/82.5 J
Nominal Fall 1.38m
Impact Criteria
Allowed Peak Acceleration 400 G
2 ms over 200 G
Allowed Duration Requirement
4 ms over 150 G
Test Equipment
Impact Test Rig Type Monorail

Variable Weight
DOT configuration
S = 3.5 kg
Headforms
M = 5.0 kg
L = 6.1 KG
 Helmet Modeling

Side view Front view Top view

Simulation Using Abaqus
 Project Completion Timeline
2023 2024
Composit Oct Nov Dec Jan Feb March April May June
e Helmet

Literature 03
Review

Thesis
Writing

Simulation 02

Manufactu
01
ring

Testing

Results

23
References
• Khurshid et al: age factors; autopsy; cause of death; covid-19; epidemiology; fatalities; forensic medicine; gender; Pakistan; road traffic accident, 2021:
https://pubmed.ncbi.nlm.nih.gov/33996319/ [1]
• Khurshid et al: age factors; autopsy; cause of death; covid-19; epidemiology; fatalities; forensic medicine; gender; Pakistan; road traffic accident, 2021:
https://pubmed.ncbi.nlm.nih.gov/33996319/ [2]
• Megan L. Bland, Craig McNally, and Steven Rowson:STAR Methodology for Bicycle Helmets, 2018:
https://vtechworks.lib.vt.edu/bitstream/handle/10919/83760/Bicycle%20STAR%20Methodology.pdf?sequence=1&isAllowed=y [3]
• Mohammed Hafzi Md Isa Mohammed syazwan Solah Aqbal Hafeez Ariffin Azhar Hamzah: Comparative Study of Motorcycle Helmets Impact Performance, 2014:
https://www.researchgate.net/publication/282590874_Comparative_Study_of_Motorcycle_Helmets_Impact_Performance [4]
• Yasuhiro Matsui, Shoko Oikawa & Naruyuki Hosokawa: Effectiveness of wearing a bicycle helmet for impacts against the front of a vehicle and the road surface,
Traffic Injury Prevention, DOI: 10.1080/15389588.2018.1498089, 2018: https://doi.org/10.1080/15389588.2018.1498089 [5]
• Intakhab khan1 (0000-0001-9006-4224), Aditya shinde2, Shresth Khandelwal3, Vinay sah4, Narendiranath Babu T: FINITE ELEMENT ANALYSIS ON DIFFERENT
MATERIALS FOR MOTORCYCLE HELMET SHELL:2019 https://www.irjet.net/archives/V6/i5/IRJET-V6I5533.pdf [6]
• Varun Agrawal, Rohit Kumrawat, Jivya Jain, Shreyas Bute, Anil Lashkari, Ashish Solanki: Design and Analysis of the Motorcycle Helmet using Finite element analysis
as per FMVSS 218, 2018: IRJET-V5I5965.pdf [7]
• Megan L. Bland, David S. Zuby, Becky C. Mueller & Steven Rowson: Differences in the protective capabilities of bicycle helmets in real-world and standard-specified
impact scenari, 2018: 15389588.2017.1388915.pdf [8]
• Javid Abderezaei 1, Fargol Rezayaraghi 1, Brigit Kain2, Andrea Menichetti and Mehmet Kurt: An Overview of the Effectiveness of Bicycle Helmet Designs in Impact
Testing, 2021: https://pubmed.ncbi.nlm.nih.gov/34646816/ [9]
• Arnaldo Jacob, Caroline Faria, Gustavo Cardoso, Klebson Reis, Mariana Motta, Thiago Meneghetti, Roberto Cammino, Aiman Shibli: Evaluation of Helmet Protection
during Impact of Head to Ground and Impact of an Object to Head Using Finite Element Analysis, 2016: http://article.sapub.org/10.5923.j.safety.20160501.02.html
[10]
• FADY ABAYAZID, KE DING, KARL ZIMMERMAN, HELENA STIGSON, and MAZDAK GHAJARI: A New Assessment of Bicycle Helmets: The Brain Injury Mitigation Effects of
New Technologies in Oblique Impacts, 2021: s10439-021-02785-0.pdf [11]
• Irfan Sadaq Shaik, Md. Abdul Raheem Junaidi, Joseph George Konnully: Impact Test on Motorcycle Helmet for Different Impact angles using FEA, 2014: j_8.pdf [12]
• Shunfeng Li, Zhi Xiao, Yunfei Zhang, Q.M. Li: Impact analysis of a honeycomb-filled motorcycle helmet based on coupled head-helmet modelling, 2021:
j.ijmecsci.2021.106406.pdf [13]
• Arnav Gupta1, Dr. Mohammad Mursaleen: Finite Element Analysis of the Motorcycle Helmet Material against Impact Velocity, 2021:
Finite_Element_Analysis_of_the_Motorcycl.pdf [14]
• Saroj Kumar Biswal, S.M.Shahrukh Rais, Karanam Krishna: IMPACT TEST ANALYSIS ON A 2-WHEELER HELMET USING 3D MODELLING AND ANALYSING SOFTWARE FOR
TWO DIFFERENT MATERIALS, 2016: IJIRT143411_PAPER.pdf [15]
• Kirk Hansena, Nathan Daua, Florian Feist b, Caroline Deckc, Rémy Willinger c, Steven M. Madeya, Michael Bottlanga,∗:Angular Impact Mitigation system for bicycle
helmets to reduce head acceleration and risk of traumatic brain injury, 2013: j.aap.2013.05.019.pdf [16]
• N.J. Mills, A. Gilchrist:Oblique impact testing of bicycle helmets, 2007: https://www.sciencedirect.com/science/article/abs/pii/S0734743X07000838 [17]
Thank You