A precision method for integrating shock sensors in the lining of sports helmets by additive manufacturing

TL;DR

This paper introduces an additive manufacturing technique to embed optical fibre pressure sensors into sports helmet linings, enabling effective impact monitoring with a scalable, cost-efficient, and unobtrusive system powered by low-maintenance batteries.

Contribution

It presents a novel additive manufacturing process for embedding sensors into helmet padding, enhancing impact detection in contact sports.

Findings

Successful embedding of optical fibre sensors in TPU helmet padding

Demonstrated sensitive shock-monitoring capabilities

System is cost-effective and suitable for mass production

Abstract

An additive manufacturing method is presented for embedding optical fibre-based pressure sensors into the lining of sports helmets to monitor head impact in contact sports. Proof-of-concept thermoplastic polyurethane (TPU) helmet padding segments with embedded sensors are demonstrated for their sensitive shock-monitoring capabilities. The system offers a cost-effective solution for manufacturing consumer products at scale, is unobtrusive, and can be powered by medical-grade cell batteries requiring low maintenance.