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"One-size-fits-all’ is definitely not a good approach to helmet design, especially for situations with the significant risk of head injury such as sports and industrial workplaces. Function of helmets is only given with perfect fit. But the complex geometry of heads was insufficiently defined by traditional measurement which captures length, width and circumference only as numerical values. Therefore, no head shape information was available so far. In contrast, 3D scanning-technology provides an innovative approach for analyzing head measurements and shapes. Scientific analyses show remarkable variations in head shapes of humans within the same head circumference. Despite the real need for head protection systems, no reliable anthropometric German head data of women, men and children was available so far. The results of the Hohenstein R&D project „Textile-based head protection systems“(IGF 16976 N) close this information gap. To collect exact three dimensional head data a specific scanning process was installed, heads of men, women and children were scanned and a database of 3D scan head data was created. Statistic evaluations as well as 3D shape analysis were conducted. Market share tables and virtual 3D shape models representing realistic head shapes of German population were generated and new innovative virtual 3D analysis methods for proving fit and ergonomic comfort were developed. 3D scanning-technology provides an innovative approach for the optimization of helmets in consideration of fit, functionality and design. In summary, the study results provide fundamental guidelines for helmet optimization in consideration of fit, functionality and design.

Using 3D Scanning for Improved Helmet Design