Evaluation of an Elastomeric Honeycomb Bicycle Helmet Design to Mitigate Head Kinematics in Oblique Impacts

Head impacts in bicycle accidents are typically oblique to the impact surface and transmit both normal and tangential forces to the head, causing linear and rotational head kinematics, respectively. Traditional expanded polystyrene (EPS) foam bicycle helmets are effective at preventing many head injuries, especially skull fractures and severe traumatic brain injuries (TBIs) (primarily from normal contact forces). However, the incidence of concussion from collisions (primarily from rotational head motion) remains high, indicating need for enhanced protection. An elastomeric honeycomb helmet design is proposed herein as an alternative to EPS foam to improve TBI protection and be potentially reusable for multiple impacts, and tested using a twin-wire drop tower. Small-scale normal and oblique impact tests showed honeycomb had lower oblique strength than EPS foam, beneficial for diffuse TBI protection by permitting greater shear deformation and had the potential to be reusable. Honeycomb helmets were developed based on the geometry of an existing EPS foam helmet, prototypes were three-dimensional-printed with thermoplastic polyurethane and full-scale flat and oblique drop tests were performed. In flat impacts, honeycomb helmets resulted in a 34% higher peak linear acceleration and 7% lower head injury criteria (HIC15) than EPS foam helmets. In oblique tests, honeycomb helmets resulted in a 30% lower HIC15 and 40% lower peak rotational acceleration compared to EPS foam helmets. This new helmet design has the potential to reduce the risk of TBI in a bicycle accident, and as such, reduce its social and economic burden. Also, the honeycomb design showed potential to be effective for repetitive impact events without the need for replacement, offering benefits to consumers.

An Air-Filled Bicycle Helmet for Mitigating Traumatic Brain Injury

We created a novel air-filled bicycle helmet. The aims of this study were (i) to assess the head injury mitigation performance of the proposed helmet and (ii) to compare those performance results against the performance results of an expanded polystyrene (EPS) traditional bicycle helmet. Two bicycle helmet types were subjected to impacts in guided vertical drop tests onto a flat anvil: EPS helmets and air-filled helmets (Bumpair). The maximum acceleration value recorded during the test on the Bumpair helmet was 86.76 ± 3.06 g, while the acceleration during the first shock on the traditional helmets reached 207.85 ± 5.55 g (p < 0.001). For the traditional helmets, the acceleration increased steadily over the number of shocks. There was a strong correlation between the number of impacts and the response of the traditional helmet (cor = 0.94; p < 0.001), while the Bumpair helmets showed a less significant dependence over time (cor = 0.36; p = 0.048), meaning previous impacts had a lower consequence. The air-filled helmet significantly reduced the maximal linear acceleration when compared to an EPS traditional helmet, showing improvements in impact energy mitigation, as well as in resistance to repeated impacts. This novel helmet concept could improve head injury mitigation in cyclists.

Characterizing Oxide Inclusions in Welded Lean Duplex Stainless Steels and Their Influence on Impact Toughness

In newly developed 2101 lean duplex stainless steel, oxide inclusions have been detected on welded metal zones after subjecting them to flux-cored arc welding with an E2209T1-1 flux-cored filler metal. These oxide inclusions directly affect mechanical properties of the welded metal. Hence, a correlation requiring validation has been proposed between oxide inclusions and mechanical impact toughness. Accordingly, this study employed scanning electron and high-resolution transmission electron microscopy to assess the correlation between oxide inclusions and mechanical impact toughness. Investigations revealed that the spherical oxide inclusions comprised a mixture of oxides in the ferrite matrix phase and were close to intragranular austenite. The oxide inclusions observed were titanium- and silicon-rich oxides with amorphous structures, MnO with a cubic structure, and TiO₂ with an orthorhombic/tetragonal structure, derived from the deoxidation of the filler metal/consumable electrodes. We also observed that the type of oxide inclusions had no strong effect on absorbed energy and no crack initiation occurred near them.

Effect of Process Parameters and Build Orientation on Microstructure and Impact Energy of Electron Beam Powder Bed Fused Ti-6Al-4V

To fully exploit the benefits of additive manufacturing (AM), an understanding of its processing, microstructural, and mechanical aspects, and their interdependent characteristics, is necessary. In certain instances, AM materials may be desired for applications where impact toughness is a key property, such as in gas turbine fan blades, where foreign or direct object damage may occur. In this research, the impact energy of a series of Ti-6Al-4V specimens produced via electron beam powder bed fusion (EBPBF) was established via Charpy impact testing. Specimens were produced with five different processing parameter sets, in both the vertical and horizontal build orientation, with microstructural characteristics of prior β grain area, prior β grain width, and α lath width determined in the build direction. The results reveal that horizontally oriented specimens have a lower impact energy compared to those built in the vertical orientation, due to the influence of epitaxial grain growth in the build direction. Relationships between process parameters, microstructural characteristics, and impact energy results were evaluated, with beam velocity displaying the strongest trend in terms of impact energy results, and normalised energy density exhibiting the most significant influence across all microstructural measurements.

Relating on-field youth football head impacts to pneumatic ram laboratory testing procedures

A youth-specific football helmet testing standard has been proposed to address the physical and biomechanical differences between adult and youth football players. This study sought to relate the proposed youth standard-defined laboratory impacts to on-field head impacts collected from youth football players. Head impact data from 112 youth football players (ages 9-14) were collected through the use of helmet-mounted accelerometer arrays. These head impacts were filtered to only include those that resided in corridors near prescribed National Operating Committee on Standards for Athletic Equipment (NOCSAE) impact locations. Peak linear head acceleration and peak rotational head acceleration magnitudes collected from pneumatic ram impactor tests as specified by the proposed NOCSAE youth standard were compared to the distribution of on-field head impacts. All laboratory impact tests were among the top 10% in terms of magnitude for Severity Index and peak rotational acceleration of matched location head impacts experienced by youth football players. As concussive head impacts are among the most severe impacts experienced on the field, a safety standard geared toward mitigating concussion should assess the most severe on-field head impacts. This proposed testing standard may be refined as more becomes known regarding the biomechanics of concussion among youth athletes.

Full-Field Operational Modal Analysis of an Aircraft Composite Panel from the Dynamic Response in Multi-Impact Test

Experimental characterization and validation of skin components in aircraft entails multiple evaluations (structural, aerodynamic, acoustic, etc.) and expensive campaigns. They require different rigs and equipment to perform the necessary tests. Two of the main dynamic characterizations include the energy absorption under impact forcing and the identification of modal parameters through the vibration response under any broadband excitation, which also includes impacts. This work exploits the response of a stiffened aircraft composite panel submitted to a multi-impact excitation, which is intended for impact and energy absorption analysis. Based on the high stiffness of composite materials, the study worked under the assumption that the global response to the multi-impact excitation is linear with small strains, neglecting the nonlinear behavior produced by local damage generation. Then, modal identification could be performed. The vibration after the impact was measured by high-speed 3D digital image correlation and employed for full-field operational modal analysis. Multiple modes were characterized in a wide spectrum, exploiting the advantages of the full-field noninvasive techniques. These results described a consistent modal behavior of the panel along with good indicators of mode separation given by the auto modal assurance criterion (Auto-MAC). Hence, it illustrates the possibility of performing these dynamic characterizations in a single test, offering additional information while reducing time and investment during the validation of these structures.

A quantitative and non-invasive vibrational method to assess bone fracture healing: a clinical case study

Orthopaedics needs a robust diagnostic tool that can help or even replace traditional radiography in bone healing assessment, thus reducing patient exposure to ionizing radiation. We used a vibrational method to assess the healing of a complex fracture treated with external fixation, exploiting a quantitative and non-invasive procedure. Callus stiffening was monitored from the time of surgery until the fixator was removed. Our approach overcomes previous limitations and involves a longer period of healing monitoring (about 9 months), very frequent tests (bi-weekly), and the analysis of a single test configuration. The healing process was monitored by analysing the percentage increments of the squared resonant frequencies (SFIs), related to the stiffness variation and the changes in the frequency response functions. The results were validated by X-rays images, and revealed that the most sensitive parameter to quantify the healing was the SFI of the first resonant frequency which increased by about 20% per month during the formation of the woven callus and up to about 50% at the end of healing completion. This study confirms the potential of the vibrational method as an alternative to radiography in fracture healing assessment.

Preliminary Material Evaluation of Flax Fibers for Prosthetic Socket Fabrication

Composite prosthetic sockets are typically made of fiberglass or carbon fiber. These fibers have good mechanical properties, but relatively poor vibration damping. Flax fibers are claimed to have exceptional vibration damping properties, with the added benefit of being a natural renewable resource and a cost-effective alternative to synthetic fibers. Flax fibers could prove beneficial for prosthetic sockets, providing lightweight sockets that reduce vibrations transmitted to the body during movement. This research used impact testing (impulse hammer and custom drop tower) on flat and socket shaped composite samples to evaluate composite layer options. Sample vibration dissipation was measured by a combination of accelerometers, load cells, and a dynamometer. Composite sockets made purely of flax fibers were lighter and more efficient at damping vibrations, reducing the amplification of vibrations by a factor of nearly four times better than sockets made purely of carbon fiber. However, the bending stiffness, elastic moduli, and flexural strength of flax sockets fabricated using the traditional socket manufacturing method were found to be ten times lower than theoretical values of flax composites found in the literature. By increasing fiber volume fraction when using the traditional socket manufacturing method, the composite's mechanical properties, namely, vibration damping, could improve and flax fiber benefits could be explored further.

Investigating the influence of Taekwondo body protectors size on shock absorption

OBJECTIVE

This study aims to compare and analyze the difference of impact force attenuation according to size and impact location on a Taekwondo body protector.

METHODS

Body protectors sized 1 to 5, were impact tested by equipment based on the specifications in the European standard manual (EN 13277-1, 3). The impactor release heights were set to match impact energies of 3 and 15 J. The impactor was made from a 2.5 kg cylindrically cut piece of aluminum. Each body protector was impacted 10 times at the two impact energies and two locations. The differences in performance for each body protector size were compared using a two-way analysis of variance with a significance level of p< 005. The effect sizes were investigated using a partial eta squared value (η2).

RESULTS

The significant mean differences between the body protector size and impact area (p< 005) and the average impact time of impact strengths 3 and 15 J were 0.0017 and 0.0012 s, respectively In addition, when an impact strength of 15 J was applied, the maximum resulting impact force exceeded 2000 N for both locations on all sizes. Furthermore, at an impact strength of 3 J size 3 significantly reduced the impact force more than the other sizes; however, size 1 showed the greatest shock absorption at an impact of 15 J.

CONCLUSION

The results of this study show that the shock absorption of body protectors does not increase according to size; i.e., a larger body protector does not reduce the impact load more effectively. To improve safety performance, we recommend a maximum impact force of 2000 N or less for all body protectors.

Evaluation of the mechanical strength and protective properties of polycarbonate toecaps subjected to repeated impacts simulating workplace conditions

The objective of this work was to examine the mechanical strength properties of polycarbonate toecaps designed for commercially available protective footwear, subjected to repeated impacts simulating workplace conditions. The effects of impacts on the toecaps were expressed as the height of toecap clearance, which has a direct bearing on the safe use of protective footwear. Changes in toecap geometry were evaluated using an originally developed methodology taking into consideration the requirements of Standard No. EN ISO 22568-2:2019. Additionally, external and internal sides of toecaps were scanned in three dimensions after each impact and reverse engineering was used to analyze deformations in toecap geometry by comparing the shape of the toecaps before and after impact. Three-dimensional scanning made it possible to measure the remaining safe distance for toes between the footwear sole and the impacted toecap surface, which is an indicator of the protective properties and safety of toecaps during use.

Impact and Post-Impact Performance of Sandwich Wall Boards with GFRP Face Sheets and a Web-Foam Core: The Effects of Impact Location

In recent years, load-bearing exterior sandwich wall boards have been adopted in civil engineering. The exterior walls of structures are often exposed to low velocity impacts such as stones, tools, and windborne debris, etc. The ultimate loading capacity, deformation, and ductility of sandwich walls are weakened by impact loads. In this study, the sandwich wall boards consisted of glass fiber reinforced plastic (GFRP) face sheets and a web-foam core. The core of wall boards was not the isotropic material. There was no doubt that the mechanical performance was seriously influenced by the impact locations. Therefore, it is necessary to carry out an investigation on the impact and post-impact performance of exterior wall boards. A comprehensive testing program was conducted to evaluate the effects of impact locations and impact energies on the maximum contact load, deflection, and contact time. Meanwhile, the compression after impact (CAI) performance of wall boards were also studied. The results indicated that the impact location significantly affects the performance of wall boards. Compared with an un-damaged wall board, the residual ultimate loading capacity of damaged wall boards reduced seriously, which were not larger than 50% of the designed ultimate loading capacity.

Football helmet impact standards in relation to on-field impacts

Youth football helmets currently undergo the same impact testing and must satisfy the same criteria as varsity helmets, although youth football players differ from their adult counterparts in anthropometry, physiology, and impact exposure. This study aimed to relate football helmet standards testing to on-field head impact magnitudes for youth and varsity football helmets. Head impact data, filtered to include only impacts to locations in the current National Operating Committee on Standards for Athletic Equipment standard, were collected for 48 collegiate players (ages 18-23 years) and 25 youth players (ages 9-11 years) using helmet-mounted accelerometer arrays. These on-field data were compared to a series of National Operating Committee on Standards for Athletic Equipment standard drop tests with a youth and varsity Riddell Speed helmet. In the on-field data, the adult players had a higher frequency of impact than the youth players, and a significant difference in head acceleration magnitude only existed at the top location (p < 0.001). In the laboratory drop tests, the only significant difference between the youth and varsity helmets was at the 3.46 m/s (61 cm) impact to the front location (p = 0.0421). Drop tests generated head accelerations within the top 10% of measured on-field impacts, at all locations and drop heights, demonstrating that drop tests are representative of the most severe head impacts experienced by youth and adult football players on the field. Current standards have been very effective at eliminating skull fracture and severe brain injury in both populations. This analysis suggests that there is not currently a need for a youth-specific drop test standard. However, there may be such a need if helmet testing standards are updated to address concussion, paired with a better understanding of differences in concussion tolerance between youth and adult populations.

Cartilage-on-cartilage versus metal-on-cartilage impact characteristics and responses

A common in vitro model for studying acute mechanical damage in cartilage is to impact an isolated osteochondral or cartilage specimen with a metallic impactor. The mechanics of a cartilage-on-cartilage (COC) impact, as encountered in vivo, are likely different than those of a metal-on-cartilage (MOC) impact. The hypothesis of this study was that impacted in vitro COC and MOC specimens would differ in their impact behavior, mechanical properties, chondrocyte viability, cell metabolism, and histologic structural damage. Osteochondral specimens were impacted with either an osteochondral plug or a metallic cylinder at the same delivered impact energy per unit area, and processed after 14 days in culture. The COC impacts resulted in about half of the impact maximum stress and a quarter of the impact maximum stress rate of change, as compared to the MOC impacts. The impacted COC specimens had smaller changes in mechanical properties, smaller decreases in chondrocyte viability, higher total proteoglycan content, and less histologic structural damage, as compared to the impacted MOC specimens. If MOC impact conditions are to be used for modeling of articular injuries and post-traumatic osteoarthritis, the differences between COC and MOC impacts must be kept in mind.

FREQUENCY CONTENT OF CARTILAGE IMPACT FORCE SIGNAL REFLECTS ACUTE HISTOLOGIC STRUCTURAL DAMAGE

OBJECTIVE

The objective of this study was to determine if acute cartilage impact damage could be predicted by a quantification of the frequency content of the impact force signal.

DESIGN

Osteochondral specimens excised from bovine lateral tibial plateaus were impacted with one of six impact energies. Each impact force signal underwent frequency analysis, with the amount of higher-frequency content (percent of frequency spectrum above 1 KHz) being registered. Specimens were histologically evaluated to assess acute structural damage (articular surface cracking and cartilage crushing) resulting from the impact.

RESULTS

Acute histologic structural damage to the cartilage had higher concordance with the high-frequency content measure than with other mechanical impact measures (delivered impact energy, impact maximum stress, and impact maximum stress rate of change).

CONCLUSIONS

This result suggests that the frequency content of an impact force signal, specifically the proportion of higher-frequency components, can be used as a quick surrogate measure for acute structural cartilage injury. Taking advantage of this relationship could reduce the time and expense of histological processing needed to morphologically assess cartilage damage, especially for purposes of initial screening when evaluating new impaction protocols.

Towards the development of a standard test procedure for mouthguard assessment

A simulated upper jaw, made from a rubber arch containing replaceable ceramic teeth and a renewable composite jawbone, offers promise in assessing the performance of custom made mouthguard designs. Impact tests, involving precise assessment of jaw and tooth fractures caused by projectiles of various energies and profiles, simulate conditions that approximate to common clinical observation. Such conditions offer the most sensitive indices for assessing both improved mouthguard designs and product quality and reliability. Damage caused by the dissipation of the impact energy may be transferred within this simulated oral cavity by minor changes to the impact conditions.