Helmet design based on 3D scanning

2015. I graduated cum laude at the TU Delft (Master Integrated Product development, Faculty of Industrial Design engineering)

Many Thanks to Lars Dekker and Charly Heusschen from EGG Helmets and Johan Molenbroek and Bram de Smit from IDE for coaching.

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Grasshopper spaghetti
A visualisation of the several steps of the project; From chin (3D scan) to neck (cushioning design) is being done by Grasshopper, all automatically.

The scientific scope of my graduation

I developed an algorithm for incorporating 3D scanning data in product design. I determined the true shape of heads and their local variations amongst a large sample group. This led to an 'ultimate fit' for the inner foam and cushioning. Therefore, it was possible to enter a different set of 3D scan data to have a different ultimate fit for regions worldwide, by exchanging the inner foam core per region.

The commercial scope of my graduation

The company EGG helmets was only producing multi-sports helmets for children so far. They wanted to enter the adult helmet market. After a market analysis, I started creating lots of concepts on paper to find their ideal new helmet shape.

Many helmet concepts
Selection of sketches
The whole process of this algorithmic helmet design process in Grasshopper