Design, optimization and additive manufacturing of an innovative bike helmet using auxetic metastructures

IF 3.4 3区工程技术 Q1 MECHANICS International Journal of Solids and Structures Pub Date : 2025-01-16 DOI:10.1016/j.ijsolstr.2025.113240

Mohammad Hossein Zamani , Mohammad Heidari-Rarani , Mohsen Mirkhalf

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Abstract

Safety helmets with high energy absorption are crucial for bike riders and represent a significant priority for the sports industry. This study proposes an innovative design of a mountain bike helmet with an auxetic re-entrant metastructure made out of thermoplastic polyurethane (TPU) for its liner and a thin layer of Polyethylene Terephthalate Glycol (PETG) for its outer shell. The metastructure is designed in SolidWorks software and the impact test is simulated according to the conditions of the EN 1078 standard in Abaqus software. Finite element modeling utilizes input data from the compression tests on 3D-printed TPU specimens. The Taguchi design of experiment (DOE) is used to find the optimal cell geometry of the metastructure and minimize the deceleration during impact tests. A fused deposition modeling (FDM) 3D printer manufactures the entire liner integrally. Two different impact test scenarios, flat anvil and kerbstone anvil, are performed on the manufactured helmet. A comparison of experimental and finite element results shows good accuracy of the numerical model. In addition to a customized helmet liner tailored to individual head shapes and sizes, the proposed liner provides low deceleration during impacts.

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来源期刊

International Journal of Solids and Structures 物理-力学

CiteScore

6.70

自引率

8.30%

发文量

405

审稿时长

70 days

期刊介绍： The International Journal of Solids and Structures has as its objective the publication and dissemination of original research in Mechanics of Solids and Structures as a field of Applied Science and Engineering. It fosters thus the exchange of ideas among workers in different parts of the world and also among workers who emphasize different aspects of the foundations and applications of the field. Standing as it does at the cross-roads of Materials Science, Life Sciences, Mathematics, Physics and Engineering Design, the Mechanics of Solids and Structures is experiencing considerable growth as a result of recent technological advances. The Journal, by providing an international medium of communication, is encouraging this growth and is encompassing all aspects of the field from the more classical problems of structural analysis to mechanics of solids continually interacting with other media and including fracture, flow, wave propagation, heat transfer, thermal effects in solids, optimum design methods, model analysis, structural topology and numerical techniques. Interest extends to both inorganic and organic solids and structures.