Protective helmet development is becoming a sophisticated engineering process that combines simulation, additive manufacturing, advanced materials, and artificial intelligence. A project involving D2H Engineering and Rand Simulation illustrates how these technologies can improve safety and aerodynamic performance while accelerating product development, tells Design News.
D2H Engineering was tasked with developing a helmet capable of surviving severe crash impacts while meeting aerodynamic requirements. Rand Simulation supported the project using Ansys LS-DYNA, which can model nonlinear materials and high-energy impacts. Simulation allowed engineers to examine how differences in helmet fit, comfort, and head shape can influence injury outcomes.
Virtual testing also reduced reliance on physical prototypes. By analyzing designs before physical testing, engineers could identify problems earlier, lower development costs, and accelerate commercialization. The approach is especially useful because helmet requirements vary considerably among sports. A downhill skiing helmet, for example, must balance impact protection with aerodynamics and peripheral vision.
Materials present another challenge. Modern foams and composites often behave nonlinearly under impact, requiring sophisticated material models to predict their performance. Additive manufacturing expands the available design space by enabling customized foam lattices with carefully controlled properties. Simulation can then help engineers optimize these structures for specific impact conditions.
The same principles extend beyond helmets. Additive manufacturing combined with simulation can consolidate complex assemblies, reducing thousands of individual components to far fewer printed parts in some applications.
Artificial intelligence is also changing simulation workflows. Traditional computational fluid dynamics calculations can require days or weeks to solve complex aerodynamic problems. AI models trained on previous simulation data can predict outcomes much faster, allowing engineers to evaluate design changes without repeatedly running complete numerical simulations.
AI, however, does not eliminate engineering judgment. It can accelerate early design exploration, while engineers remain responsible for final validation and critical decisions. Together, simulation, additive manufacturing, and AI are creating a more integrated approach to developing safer, higher-performing protective equipment.