• Document: 599 Fall Final Report
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DESIGN OF A HELMET by Chia-Yuan Chang Chih-Hsiang Ho San-Yi Chang ME 499/599 Fall 2003 Final Report Abstract Starting from engineering analysis, a model for engineering optimization is developed. Then, we use the survey data collected from the class to develop a microeconomics (demand) model to predict the sales when our products hit the market. At the meantime, we also conduct a deep literature survey to address how we couple customers’ demand with our design and manufacturing processes so that our cost estimation model is refined. Finally, by solving the optimization coupled with the engineering and marketing model, we propose a product family featuring 3 different products targeting commuters, amateurs, and professional racers. Each product specification is stated and the compromise arose from sharing components to achieve maximum profit is also discussed. Please note that all intermediate results are left out on purpose for integrality since our ultimate goal is using the developed models to analyze and introduce 3 different products on the market. Hence, a future business plan is also included in our appendix. 1 Index 1. Summary on Helmet Design Considerations ....................................................4 1.1 The Product Design Problem and Challenge .................................................. 4 1.2 Design Consideration: Ideas at the Initial Stage............................................ 4 1.3 Design Criteria ........................................................................................................... 5 1.3.1 Reduce the risk of mild traumatic brain injury (MTBI) ..................5 1.3.2 Stability and Fit ..................................................................................5 1.3.3 Comfort ...............................................................................................5 2. Engineering Models .............................................................................................5 2.1 Structure of Helmet .................................................................................................. 5 2.1.1 Visor ....................................................................................................6 2.1.2 Outer Shell..........................................................................................6 2.1.3 Comfort Padding ................................................................................6 2.1.4 Ventilation System..............................................................................6 2.1.5 Retention System ................................................................................6 2.1.6 Liner(Foam) .......................................................................................6 2.2 Standard for Helmet Strength .............................................................................. 7 2.3 Standard for Head Protection .............................................................................. 7 2.4 Nomenclature ............................................................................................................. 7 2.5 Establishment of Engineering Model................................................................. 8 2.5.1 Design of Foam Density.....................................................................9 2.5.2 Design of Foam Thickness ..............................................................11 2.5.3 Foam Material Choice .....................................................................12 2.5.4 Design of Shell Thickness and Material Choices ...........................12 2.6 Helmet Design Optimization ............................................................................... 13 2.7 Solution for Optimization .................................................................................... 16 3. Microeconomics Models via Market Survey ...................................................17 3.1 Quality Function Deployment (QFD) ............................................................... 17 3.1.1 Key Benefits ......................................................................................17 3.1.2 Our Approach ...................................................................................18 3.2 Couple Customer Demands with Engineering Ideas .................................. 18 3.2.1 Comfort/fit ........................................................................................18 3.2.2 Style ..................

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