A custom-made helmet? Not a dream any more.

FOR IMMEDIATE RELEASE
(Free-Press-Release.com) March 12, 2008 -- The European project Custom-fit aims to produce fully personalised consumer goods at a cost effective rate.

The motorbike helmet is one of the case studies chosen in this project. Currently, the Custom-Fit application field is quite wide, not only in the consumer goods market (as motorbike seats) but also for medical applications (knee and jaw surgical implants and prosthesis).

The process starts by capturing the geometrical characteristics of the consumer’s body using a 3-dimensional scanner. Then, specialized CAD software facilitates adaptations from a standard product design to individual consumer features. Finally, the customised part is manufactured with newly developed, high productivity, additive techniques, perfectly suited to the production of one of a kind goods.

For the case of the helmet, the starting point is the the 3D scanning of rider’s head shape, carried out using a laser scanner developed by Human Solutions. From the scanned surface model adaptations are made on a standard design, resulting in a helmet perfectly shaped to the rider's head (carried out with CAD tool from Delcam). Finally the customised part (the liner) is manufactured using a new Rapid Manufacturing machine called Powder Printing Process and developed by DeMonfort University which builds a real 3D model from the design.

Five samples of customised helmets have already been made for five professional motorbike test riders. The next step will be to perform ‘long ride’ tests in order to verify the real improvement in comfort perceived by riders with the new helmets. Objective measurements will be also made by putting pressure sensors between helmet and head in order to measure the actual pressure exerted by the helmet on the head. Other issues, as noise levels and the effectiveness of air flow channels, will be evaluated and recorded.

Obviously, the main issue with helmet is still safety! And this is greatly improved in all new customised helmet by using the same amount of expanded polistyrene as used in standard and certified helmets (this material is principally responsible for the function of shock absorption). Moreover, some special customisation of the mechanical characteristics of the customised liner should increase safety level.

The project has also dealt with the reorganization of service and delivery, by studying a new way to interact with customers form the moment they start the order process, to the point in which the customised helmet is delivered. All modification to the supply chain have been studied.

Initially the rider/customer will probably face an increase in price and delivery time to have a Custom Fit helmet. Nevertheless they will be rewarded by being the owner of a unique, custom-made helmet, not only more comfortable but safer as well.

And of course they will also be the proud pioneers of a new manufacturing era, the Mass Customisation age, that we believe will replace the Mass Production age in the very near future.

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