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Team Leader: Chris Casella Nate Marshall Tiffany Gundler Scott Quenville Christian Blank Kayla Wheeler P15550: Customized Personal Protection Headwear Preliminary DDR

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AGENDA Background General Information Current Product Additional Deliverables Stakeholders Problem Definition Customer and Engineering Requirements Benchmarking Specifications System Analysis House of Quality Functional Decomposition Systems Design Alternatives Considered and Pugh Charts System Architecture Engineering Analysis Weeks 9-12 Update Expert Advice Test Rig Design and Pugh Chart Test Plan and Results Preliminary Workflow Project Planning Risk Management Updated Project Plan

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PROBLEM STATEMENT Current State: Limited to manufactured helmets in contact sports Desired State: Custom Fit helmets using 3D printed Thermoplastic Urethane (TPU) as the padding to absorb energy from the impact Project Constraints: Overall helmet weight (benchmarked against competitors) Durability (Target Age: 15-25) Manufacturability Biocompatability $1000 budget Key Goals and Deliverables CAD models of different 3D printed cellular materials Semi-automated workflow for sending scanned dimensions to SolidWorks to the 3D printer 3D printed, customized, energy absorbent pads Custom fitted football helmet with pads Drop test rig with impact sensor feedback

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BACKGROUND

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1.6-3.8 million sports related head injuries in the U.S. 2012 - 261 diagnosed concussions o.81 conc/game 2013 - 228 diagnosed concussions o.71 conc/game Repeated head injuries result in Chronic traumatic encephalopathy On august 29th, 2013 a lawsuit was taken against the NFL for a total of 765 million dollars. Manufacturers Include: Riddell, Schutt, Rawlings, and Xenith.

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CURRENT PRODUCT- Schutt ION 4D Adult Football Helmet The new Schutt helmet uses a unique facemask design that allows easy removal Uses Thermoplastic Urethane (TPU) padding that allows for higher cushioning value Scored better ratings in impact testing than the Xenith X1

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STAKEHOLDERS Denis Cormier Athlete Trainer Medic Manufacturer Hospital Insurance?

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Problem Definition

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CUSTOMER NEEDS Key: 9-Very Important 3- Important 1- SImportantomewhat

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ENGINEERING SPECIFICATIONS Key: 9-Very Important 3- Important 1- Somewhat Important

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BENCHMARKING SPECS A - instantaneous acceleration

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SYSTEM ANALYSIS

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HOUSE OF QUALITY Key: - Strong Correlation O- Moderate Correlation - Weak Correlation

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FUNCTIONAL DECOMPOSITION 2141 MSD1 13026 annotated System Level Design Review Presentation

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Systems Design

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ALTERNATIVES CONSIDERED

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(PUGH EVALUATION CHART)

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ALTERNATIVES CONSIDERED

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SYSTEM ARCHITECTURE

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ENGINEERING ANALYSIS NEEDED G-Force requirement What will the helmet need to withstand in order to protect players from concussions? Durability How many impacts will the padding have to be reliable for? How many seasons? Test Rig Can we design a test rig that matches the specifications of standard testing equipment that is repeatable, and will allow us to test different impact scenarios? Prototype Cost Approximately how much will a prototype cost?

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OTHER CONSIDERATIONS Moisture Retention Testing Linear Hexagonal With or without material cover Material response to temperature change Playing in Texas? Playing in Upstate NY? Biocompatability Is material cover necessary? Print Speed and Time If there is a concussion suffered using our padding, should we replace it?

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Week 9 - 12 Update

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Expert Advice Rachel Silvestrini-ISE Department Chris Pietrzak- BRG sports Joe Abraham- Materials Testing Lab Patent Attorney

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Test Plan Expert Advice: Rachel Silvestrini (ISE)

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Compression Test Results SampleSchuttBlock 1Block 2Block 3Block 4Block 5Block 6Block 7Block 8 Peak Force (lbs) 504.141.186.0132.2173.226.4120.4266.0457.1 Deflection (inches) 0.400.110.19 0.110.180.19 PSI298.110.2721.533.0543.36.630.166.5114.28 Block 1: 5% Ninjaflex Block 2: 15% Ninjaflex Block 3: 30% Ninjaflex Block 4: 45% Ninjaflex Block 5: 5% Filaflex Block 6: 15% Filaflex Block 7: 30% Filaflex Block 8: 45% Filaflex Expert Advice: Joe Abraham (Materials Testing Lab)

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TEST RIG Design Considerations from Week 6: Accelerometer inside the helmet, on the base or both? Must be dropped from a height that will allow 72 in. of free fall. Single rail or twin wire guided? Is there a way to capture rotational forces on the head?

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WEEK 9 TEST RIG Two Rail vs. Single Rail Guided Pin Release vs. Mechanical Latch

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WEEK 12 DESIGN Two-Wire Guided Aluminum Carriage Bill of Materials

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Addressing Design Considerations from Week 6: Accelerometer will be placed at the center of gravity in the headform to measure G- force on head To measure energy that padding absorbs, an additional accel. can be placed on outside Will allow 72 of free fall. Is there a way to capture rotational forces on the head? Expert Advice: Chris Pietrzak (BRG sports)

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BILL OF MATERIALS FOR TEST RIG

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FINITE ELEMENT ANALYSIS Static Testing Dynamic Testing

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Solidworks 3D Scans

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Combined Scans

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Extra Testing Protocols Cleaning Test Soak Test Durability Test Customer Survey

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Workflow Diagram

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Project Planning

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RISK ASSESSMENT IDRisk ItemEffectCauseLikelihood Severit y ImportanceAction to Minimize RiskOwner Describe the risk briefly What is the effect on any or all of the project deliverables if the cause actually happens? What are the possible cause(s) of this risk? L*S What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring? Who is responsible for following through on mitigation? 1 Is TPU foam the best option for preventing concussion impacts Wont change our project. However future MSD projects could be focused on the new material New types of foam are discovered 313 This concern is outside the scope of the project. We accept that this is a high possibility None 2 Cell wall stiffness will affect density calculations and segment size This will primarily determine how big our foam segments are Printer capability339 Design around this parameter Kayla/Tiffany 3 Time requirements to scan, import, and print must be short to make production practical Slow production will hinder product adoption Printer speed, material required 326 Reduce material requirement without increasing impact forces to the head Nate/Tiffany 4Will the design and testing phase require more material than expected Increased project cost Varied designs to test 224Use computer modeling to insure the design is viable before actual testing Kayla/Tiffany

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5 How will 3-D printed foam help reduce concussions from rotational impacts Effectiveness at concussion prevention is reduced Foam is primarily used for linear impacts. Straps can help with rotational impacts 33c9 A neck guard while not within the scope of the project could be helpful in reducing rotational forces on the neck Nate/Scott 6Printer failureDelayed printing time Human error or machine malfunction 133 Learn how to properly operate printer within its parameters Chris 7Printer availabilityDelayed printing time Other students needing printer time 122 Plan printing time a week in advance with customer Chris 8Printer printing sizeLimits printing segment size Defined printer capability 224Design the segment size within printer capability Kayla 9Printer operability Printer can malfunction and delay printing requirements Ignorant operation of printer 132 Learn required skills to operate printer efficiently Chris 10Customer accessibility Required answers could delay schedule Dennis likes to travel 326 Plan meetings in advance. Constant email contact with customer Chris 12 High test rig costs/failure Go over budget building test rig/failure can delay foam testing Expensive parts/sensors. Improper build techniques 224 Visit material design lab to witness proper build techniques Christian 13 Sense software and scanner produce incomplete scans Extra time reproducing complete scans Limited capability of Sense hardware and software 111 Expect extra time to obtain complete and usable head scans/check with Dennis Nate/Tiffany 14Integrating solidworks and scanning software Frustration with obtaining custom segment sizes Limited capability of Talking between softwares 122Check with Dennis/team members Nate/Tiffany

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15 Acceleration sensor accuracy Inaccurate measurements of impact forces Inefficient placement or lower quality sensor 121 Preliminary testing will show how good a sensor we need Christian 16 Failing to meet project plan deadlines Fall behind schedule and miss deliverable due dates Related to numerous other concerns and risks 224 Constant contact with team members. Be willing to ask if you need help Chris 17 Cracked plastic helmet during testing Increased cost for extra helmet and delayed testing time Hard testing impact236 Research previous test plans. Did they have this problem within test parameters? Scott 18 All printed designs do not meet requirements spec Unmarketable idea. Maybe printed TPU is inefficient compared with marketed helmet foams 339 Complete lots of testing. Exhaust all options Kayla Christian 19Adhesive failing Inaccurate force measurements. Failed test Adhesive used to apply foam segments fails 122 Durability issue most likely apparent during testing. Apply more adhesive Scott 20Material sensitivity to water/sweat and cleaning solutions Does not meet bio- compatibility and testing parameters TPU form does not respond well to wet conditions 122Prior TPU material analysis has shown this is a non-issue with this foam. However printing could change this Kayla 21Helmet durability Test fails the required parameter Foam is not durable/helmet breaks during testing 224 Redo design for next test with high emphasis on durability Scott 22Loss of partsIncreased budget cost. Delayed project We lose parts for the project 133Materials required to be locked up after use Chris

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PROJECT PLAN UPDATE

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Complete more testing Create Test Rig Force simulation in Solidworks Print more padding

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QUESTIONS