Impact performance of innovative corrugated polystyrene foam for bicycle helmets

Expanded Polystyrene (EPS) is a common material used to manufacture the inner foam liner of a bicycle helmet due to its outstanding energy absorption characteristics and light-weight property. The current research presents a novel corrugated expanded polystyrene (EPS) foam design concept which is used to enhance the impact dissipation of bicycle helmets from the safety standpoint to reduce head injuries and make them lighter. The baseline comparison study under impact for different foam configurations is compared with a conventional EPS foam sample without corrugation. Corrugated foam designs under current investigation are 12.5–20% lighter and provide up to 10% higher energy absorption. The details of the novel manufacturing concept, CPSC 1203 helmet impact tests, high-speed camera study to understand the differences in the failure mechanisms are deliberated in this paper.