Post on 08-Jun-2018
COMPETENCE IN TEXTILES
Using 3D Scanning
for Improved Helmet Design
Dr. Jan Beringer │ Hohenstein Institute
Hohenstein Webinar │ June 17th, 2015
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Introduction
Increasing number of users
• Growing markets in job, leisure and sports
• From children to seniors
• Skiing: 16 million skiers in GERmany
• Biking: 68 million bikes in GER, not all bikers wear helmets
• Industry: 10 million workers in GER with need for head protection
• Furthermore: Forest operation, fire dept, police, military, inline
skating, rock climbing, horse riding, motorcycling, canoeing and
rafting …
• Growing safety demands by awareness
both legal regulation and voluntary motivation
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Introduction
The Facts / Findings
• Helmets avoid or reduce the risk of head injuries
• 2011: 79.000 notifiable accidents at work with head injuries were
(according to German statutory accident insurance)
• Head injuries often lead to secondary damage like paralysis and /
or speech disorder
• Economic benefit: Reduction of insurance expenses, patient care
and rehabilitation
• Consumer acceptance is needed
Only wearing a helmet can prevent from severe head injuries !
• Fit (and wearing comfort) optimized helmets are needed !
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Introduction
The Challenge
• “SizeGERMANY” sizing survey showed remarkable variations in
head shapes within the same head circumference
• Additional high-resolution anthropometric head data is needed,
in particular shape information
• Market shares in head shape are needed for best market coverage
• Industry standards do not comply with the state of technology
anymore, head shape information is missing totally
• Influence of hair on the size measurements and helmet fit is unclear
Important basic information for optimized helmet
development is not available
Person 2
Person 1
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front
back
Circum-
ference
58 cm
back
front
Visual comparison – male subject (view from top)
male 1
male 2
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State of technology
Worldwide head-sizing related activities:
• CAESAR-project, 1997-2001 (NL/US)
• NIOSH Anthropometric Survey of Respirator Users, 2001-2004 (US)
• SizeChina (2006): Anthropometric head survey and digital database of
Asian heads and faces for use by manufacturers (about 1600 Scans)
• 3D Facial Norms Database (https://www.facebase.org)
3500 healthy Caucasian individuals age 5-40 (US)
• Various papers (US & CAN):
- Head-and-face shape variations of U.S. civilian workers (2013)
- A simple and standardized method for analyzing head and face
morphology of a population sample (2010)
- Sizing trials of a prototype aircrew helmet (2009)
- Principles of Fit to Optimize Helmet Sizing (2006)
- Helmet accommodation analysis using 3D laser scanning (2000) etc.
Head shape comparison - Size China
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Aim of the Hohenstein study
Results:
• Up-to-date face and 3D head measurements and head
shapes of men, women and children in Germany
• German market share tables of sex, age and head shape types
• Head specific grading guidelines
• Virtual 3D-head shape models
• Guidelines and design characteristics for optimized
development considering fit, ergonomic comfort,
thermophysiological comfort and hygiene
The Aim is the improvement of head gear systems
considering fitting plus comfort and function
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• Detailed analysis of existing 3D Scan data of
Hohenstein’s own database (17,000+ scans)
• Acquisition of additional high resolution
3D Scan data from typical head shapes
• Definition of measurements and methods
according to established standards like (ISO
7250, SizeGERMANY etc. plus new
additional head and face measurements)
Step 1 of the Hohenstein study and results
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Available 3D Scanner Systems
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3D Scan-Quality
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3D Scan experimental setup
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• Analysis und statistical evaluation of
3D-scandata of men, women and children
• 3D-head shape analysis
• Definition of basic 3D head shapes
• Definition of size ranges
according to sex, age
and head shape types based
on percentage shares
Step 2 of the Hohenstein study and results
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Men & Women:
Head circumference - percental distribution
0%
5%
10%
15%
20%
25%
30%
52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
Kopfumfang [cm]
Kopfumfang: Prozentuale Anteile - Männer und Frauen
Männer
Frauen
0,03%0,16%
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Boys: Head circumference over age groups
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Girls: Head circumference over age groups
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Men & Women: Rage of head width
(correlation head width vs. head circumference)
Korrelation Kopfbreite zu Kopfumfang
14,0
15,0
16,0
17,0
18,0
19,0
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Kopfumfang [cm]
Ko
pfb
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cm
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FrauenMänner
MAX
MIN
Mittlere Spannweite 2,5 cm
Gr.58 = 3,4 cm Spannweite
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Men & Women: Definition of head shapes and types
(correlation head width vs. head circumference)
Korrelation Kopfbreite zur Kopfumfang
13,5
14,0
14,5
15,0
15,5
16,0
16,5
17,0
17,5
18,0
18,5
19,0
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Kopfumfang [cm]
Ko
pfb
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cm
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rund
oval
normal
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The 5 defined/extracted average head types
normal oval oval extremrundrund extrem
+ 0,8cm +0,8cm +0,8cm + 0,8cm
+ 0,4cm + 0,4cm + 0,4cm + 0,4cm
X round round normal oval X oval
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Men: percental distribution head types
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Women: percental distribution head types
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Head height types (…helmet belt)
Definition of 5 head hight types
normalX short short long X long+ 2 cm + 2 cm + 2 cm + 2 cm
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Average head shapes as 3D data available
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• 3D Scan system and experimental setup defined
• 3D-scandata of men, women and children analyzed and
statistically evaluated
• 3D-head shapes analyzed and 5 basic types defined
• Size ranges according to sex, age and head shape types
based on percentage shares defined
• Average head shapes in various sizes available as 3D data
Summary
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Thank you for your kind attention
Hohenstein Institute America, Inc.
Samuel B. Moore, Ph.D & Ben Mead
1688 Westbrook Ave | Burlington, NC 27215 | USA
s.moore@hohenstein.com | b.mead @hohenstein.com
www.hohenstein.us
Hohenstein Institute
Dr. Jan Beringer & Simone Morlock
Schloss Hohenstein | 74357 Boennigheim | GERMANY
j.beringer@hohenstein.de | s.morlock@hohenstein.de