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Reinventing Safety

Mass-Customized Bicycle Helmets

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Introduced a fully automated design-to-production workflow for bicycle helmets
Achieved personalized fit and safety through algorithmic design based on individual 3D head scans
Enhanced helmet safety and comfort with optimized airflow and shock absorption via unique algorithmic patterns and 3D-printed silicon inlays

The Challenge

The project aimed to revolutionize bicycle helmet safety and comfort by shifting from mass production to individualized manufacturing. Traditional helmet design tools and methods limited creative freedom, making it challenging to engineer helmets that fit the diverse shapes of human heads while ensuring optimum performance. The team, alongside Hyperganic Core, faced the task of creating a scalable, automated process to design helmets that provide a personalized fit, superior aerodynamics, and enhanced safety for every cyclist.

The Process

Inspiration for the solution came from the potential of Algorithmic Engineering to cater to individual needs by automating the design process. The team developed a workflow that begins with a cyclist's 3D head scan, which then informs the generative design engine within Hyperganic Core. This engine integrates crash impact statistics and predefined helmet shapes to produce a custom-fit helmet. Overcoming the hurdles of translating varied biometric data into functional designs, the team devised algorithmic patterns to optimize protection and airflow, marking a departure from one-size-fits-all models.

The Results

The end product is a line of 3D-printed helmets uniquely tailored to each cyclist's head, offering unmatched safety and comfort. The use of algorithmic design not only made it possible to adjust internal structures for individual fit but also to enhance aerodynamics and reduce material use without compromising safety. This innovative approach to helmet manufacturing sets a new industry standard, demonstrating the tangible benefits of integrating Algorithmic Engineering and 3D printing in consumer goods production.

This case study showcases a significant advancement in personal protective equipment, leveraging state-of-the-art technology to meet the specific safety and comfort needs of cyclists worldwide.