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

IF 3.8 3区工程技术 Q1 MECHANICS International Journal of Solids and Structures Pub Date : 2025-03-15 Epub 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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一种新型自行车头盔的设计、优化及增材制造

具有高能量吸收率的安全帽对自行车骑手来说至关重要，也是体育产业的重要优先事项。本研究提出了一种山地车头盔的创新设计，该头盔的内衬由热塑性聚氨酯（TPU）制成，外壳由薄层聚对苯二甲酸乙二醇酯（PETG）制成。在SolidWorks软件中设计了元结构，并在Abaqus软件中按照en1078标准的条件进行了冲击试验模拟。有限元建模利用3d打印TPU样品的压缩测试输入数据。采用田口实验设计（DOE）来寻找元结构的最佳单元几何形状，并使冲击试验中的减速度最小化。熔融沉积建模（FDM） 3D打印机将整个衬垫完整地制造出来。在制造的头盔上进行了平砧和石砧两种不同的冲击试验。实验结果与有限元结果的比较表明，数值模型具有较好的精度。除了根据个人头部形状和尺寸定制的头盔衬垫外，拟议的衬垫在撞击期间提供低减速。

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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.