My AS DT Coursework, no mark until June/ July

1. Compare
And
Contrast

2. •
Product Introduction:
The Products I am going to investigate are the design of the latest American Football helmets, which have been certified for the 2011- 2012 season and downhill/
off road mountain bike full face helmets.
• The primary functions are predominately the same for both types of product. This is to protect the head from sudden blows from different directions
The development
timeline of
American football
helmets
The popularity of American Football is Downhill mountain biking is a relatively new sport. The first downhill time-trial race
took on October 22, 1976 on a fire-road in Fairfax California and ten riders made the
obviously great in the USA. However, it has
1300 feet descent in about 5 minutes. The road was named Repack Road after the
been making a breakthrough in other event because it was necessary to repack the single rear hub brake after each descent
continents, especially in Europe (where of the road. The bikes used were based on beach cruisers, which had a single rear
there was an NFL until 2007). In England brake that worked by pedalling backwards and it always had to be filled with grease.
This was to prevent a “metal to metal” brake from snatching. The heavy use of the
there are now several leagues (Youth, brake during the descent caused the brake to over-heat, which melted the grease
Junior, Adult, University and Flag) all of until it drained from the hub and then it required repacking. The first bikes used for
which have several divisions and a Brit Bowl descending were known as "klunkers" or "paperboy bikes" - coaster brake cruisers
using balloon tires and were first imported to America by Ignatz Schwinn.
at the end of it. Also, the NFL itself has been
bringing international league games to Charlie Kelly and Gary Fisher, who were two of the race organisers and also
Wembley and 2011’s game will be the first competitors of the Repack Downhill, founded their company in 1979 and gave the
sport the name of Mountain Biking. The sport grew enormously during the 1980s and
where the teams will hold a talent camp for downhill riders continued to use either rigid or limited suspension travel bicycles.
16 - 19 year olds, which gives UK talent the The development timeline of Purpose made downhill bikes were not manufactured until the 1990s and
opportunity to attend high school or college incorporated innovations in their design such as dual crown suspension forks and
in the USA on a scholarship.
full faced downhill biking disc brakes, as well as very elaborate frame suspension designs.
helmets Riders from all disciplines of cycling started to focus on downhill and many BMX
The appeal of the helmet itself is more racers made the crossover to Mountain Biking, including champions such as John
materialistic. Helmets are coloured and Tomac (Team Tomac Bikes) and Brian Lopes. They influenced the increased difficulty
of the design of many courses, especially in the design of the big jumps and drops
styled to team specifications and usually aspects of downhill. Downhill biking came into its own when the sport was included
come in four sizes. Another appeal is the at the first UCI Mountain Bike Championship, which was held in 1990 in Durango,
feel that the user can get of being Colorado.
“invincible” or “large” when combined with Protective clothing for the safety of the riders had to be improved as the bike
the shoulder pads. However, this can technology developed and this included the helmets. The latest helmet design
evolved from the traditional road bike helmet. As the tracks started to develop in
sometimes be a problem, as the main areas like the hilly forests (e.g. Wistler, Canada) and urban favelas (e.g. Rio de
purpose is to protect the player’s head. Janeiro, Brazil) the protective requirements changed. Due to obvious problems with
potential facial and head injuries, it was decided that the certified helmet had to be
“full-faced”. This would absorb more impact and enables full customisation by the
The league (NFL) is currently investigating
user , for example either with vinyls, stickers, sponsors logos or any other desired
the reasons for the current average of eight add-on.
concussions a season per player, to help
However, wearing the helmet does not necessarily prevent the user from incurring
prevent them and also make youth games concussions or any other impact related injury and the technology behind the helmet
Original
safer in the future. It is also thought to be “hairnet” is continuously being investigated and improved.
linked to advanced signs of Alzheimer’s in “661” is one of the leading companies behind downhill biking and motocross
ex-players. protective clothing and have some of the best helmet technology in the world.

3. Product Specification: Schutt Ion 4D
Function:
Materials and Components: • To protect the user’s entire head from continuous Form:
• The majority of the helmet exterior is made of a hard polycarbonate composite alloy blows from all angles Over the years, the shape of the helmet has been developed for the following-
• To glance off blows so that impacts are not direct, the shell is offset to the internal
Materials, • To reduce the initial force of impact components of the helmet, with a mall gap in bet ween to dissipate the impact energy
• ThermoPlastic polyUrethane (TPU) Crown Cushioning and AiR Maxx (TPU) Jaw Pads inside helmet- • To look aesthetically pleasing in terms of team design further
• First elastomer to be made using thermoset methods and effectively sales based on these professional • Large offset/ standoff shell to allow more and bigger TPU to fit inside the helmet and
users wearing it also to absorb more of the force from impacts
• Comes in a wide range of hardness grades
• To be suited to players of all ages (in terms of head • The shape is very aerodynamic and looks “cool” which adds to popularity of sales and
• outstanding abrasion resistance, size and shape) and position (in terms of face cage effectively the speed of a player (including breaking through tackles with the sleeker
• good low temperature flexibility, needed) shape)
• oil resistant, • Face cage needs to be able to block and players hands • Team customisation is another great aspect of this helmet. There are over 50 different
from entering from the front, without the sacrifice colour options, which come in either pro gloss, kandy, pearl and metal flake accent. In
• great load-bearing capability of loss off vision addition to this, professional and college players have their team logo and other designs
• Additives can improve dimensional stability and heat resistance, reduce friction, and increase painted onto their helmets, but these are usually stuck on with 3 mm thick vinyl cut to
flame retardancy, fungus resistance, and weatherability shape via a CAD/ CAM process. This makes them durable enough to withstand at least a
season of collisions. Award decals are also custom ordered by teams for players with an
• Resulting in- better Heat Management, resiliency and hygienics
Picture showing how close the outstanding performance.
Components,
brain is to the surface of a • The shell is made from a desired mixture of polycarbonate alloy, which is fed in pellet
• Titanium face cage- form into an injection moulder
Titanium face cages are nearly 50% lighter than normal face cages and stronger than stainless steel., and
regular helmet, therefore the • All of the components need to be anthropometrically suited to a human head
are just as affordable. The normal carbon steel blends of face cages are also available force of the impact will directly • Shell is lacquered after it has been painted, to protect the finish and make the shell more
Components, affect the brain without any durable. It also adds to the aesthetics
• Moisture Management Pad- reduction or absorption or force
• Made from a variety of moisture absorbing materials, placed in layers around an inflatable
bladder
• SUREFIT Air Liner-
The t wo-piece air liner has t wo inflation ports, which gives a precise custom fit and is made from a soft, but
durable anti-microbial material, that fits on to the forehead pad
• Valve Attachment System-
Performance Requirements:
A hook and loop attachment system locks the inflation valves of the inflatable bladders (attached to the • Shell
TPU) into place, • Must be highly durable to continuous impacts (i.e. not crack or shatter
• Quarter Turn Release- • Must be lacquered to add protection to the surface finish and also to waterproof it and make it easy to
The attachment system for the face cage maintain
• Energy Wedge face cage- • TPU -
The Energy Wedge face cageface cage acts as a shock absorber for the ION 4D • must be resistant for day to day use with minimal maintenance
• Chin Strap Attachment- • SUREFIT Air Liner-
Because the Energy Wedge face cage is stronger than traditional face cages, the chin strap can be attached • To increase the user’s comfort, by removing sweat from the head
through the face cage. Other attachment methods, such as the 4-Point High, can still be used as the ION 4D • Valve Attachment System-
is pre-scored for the installation of chin strap snaps. A hard or soft cup chin guard can be chosen
• so there is no struggle to keep the valve aligned to the helmet shell
• Nose Bumper-
• Quarter Turn Release-
• Made from ABS, with either the Schutt logo or custom logo imprinted, it also holds the top of the
face cage in place • which locks it into place, but if needed a simple quarter turn of the screw releases the face cage for the
quick and easy access in an injury situation, without too much head movement
• A neck bumper- Made from ABS, with either the Schutt logo or custom logo imprinted
• Energy Wedge face cage-
• Large Ventilation Holes-
• absorbing up to 15% more impact from direct frontal impacts than traditional face cage. It is stronger
• Fasteners- There are at least 4 snap fasteners to attach the chin cup straps to, made from either a than traditional face cages and gives a wide, unobstructed view of the entire field of play
nickel/ brass alloy or ABS. These are paired at either a low, high or back position. These are also used to Illustration on
• To protect the user’s face from heavy impacts
attach the jaw pads as their sizes can vary. how
• Energy Wedge must not jam when compressed during impact
concussions
• Nose Bumper-
using regular,
• This not only keeps the face cage aligned with the helmet, but it also helps to absorb frontal impact to
none cushioned the forehead
helmets occur • Neck Bumper-
TPU • Is vital to prevent neck injuries from the thin edge of the base of the helmet
Cushioning • Ventilation-
System and • To compensate for the removal of the sweat to cool the user
Surefit Air liner • Six crown vent holes provide maximum air flow for better heat management

4. Product Specification: Schutt Ion 4D
An example of a helmet with a Scale of Production and Cost:
poor attachment system and • All components must be mass produced, to deal with
An example of the countless
the high popularity and consequent sales, especially
too much flexibility in its shell to serious high school and college teams, who will bulk number of collisions during the
material buy custom designs and also buy regularly to replace
sport, which can affect the
damaged or overused helmets, which need to be
reconditioned users head
• Retails at £400 when first produced, now £240
after 2 years (some slight changes made, but still top
of the range)
Quality:
• Exterior Shell-
• Must be completely smooth and untarnished
• Logos must be right colours and not smudged (if painted) or lumpy (if vinyl) Another example of a poor
• Edges must be rounded with a wide radius due to health and safety if the
edges on the neck
helmet design, causing the User Requirements:
• Snap Fasteners-
player to be susceptible to • Needs to protect the head from blows from all angles,
which would consequent in severe head injury or
• Must be able to withstand repeated use sever facial injuries concussion
• Chin cup-
• Hard, the cushioning must be unused/ indented and fit the right sized hard • To feel comfortable
cup, with its edges completely rounded • To be affordable
• soft, stitching must be sealed to the synthetic leather and not loose
• Needs to fit typical head sizes and player positions
• Face cage-
• Must have its joins smoothed and rounded and be symmetrical
• Parts are easy to replace
• User can customise helmet in terms of graphics/vinyl
• TPU-
stickers
• Must be the right shape for the helmet and not be cut roughly
• Machine screws/bolts are of an ISO metric screw
• Whole helmet-
• Must be tested with various impacts at critical angles to deduce the quality
thread which conforms to all helmets
of absorption • Helmet can be removed easily in case of injury
• Open cage with three horizontal bars, no vertical bar
above the nose – enables better visibility
Manufacture:
• The shell is injection moulded using pellets of a
The New York specified polycarbonate alloy
A cross section of the Ion 4D,
Giants No. 27 • TPU is reaction product of a di-isocyanate and long and
showing the TPU cushioning,
short chain polyether, polyester, or caprolactone
Running Back glycols the bladder, the jaw pads, the
Brandon Jacobs • Face cage is made my extruded titanium wire, which is bumers and the shell
wearing his bent and welded by automated machine and then
coated in a cellulose paint and hardened in an oven at
Schutt Ion 4D, various stages to make it chip resistant, but without
making him stand getting rid of the small flex
out in the field • Face Cage- the Titanium is extruded into 10mm wire
and then MIG Welded to the required design. It is then
with the sleek and painted by an electroplating process
warrior like design • Snap Fasteners- the male part is always made from a
nickel and brass alloy, but on the chin cup straps an
alternative ABS female half can be used
• All parts are batch or mass produced to keep up with
the high demand and different order styles
• All components are put together on a production line

5. Product Specification: 661 2011 Evo
Carbon Full Face Downhill/ Off-road
Bike Helmet
Materials and Components: Form:
Materials, The design of a downhill bike helmet stems from the
• Carbon fibre mesh positioned “Hairnet.” However, the needs of downhill biking being a
thrill seeking high speed sport mean more impact
within fibreglass shell
protection is needed as well as a stylish look.
•for lighter weight. • To glance off blows, so that impacts are not direct
• The 3K Carbon weave pattern increases the strength, whilst reducing the weight • The shape is very aerodynamic and looks “cool” which
• Intake and vent holes are integrated into the shell design to help keep the adds to popularity of sales and effectively the speed of
airflow constant the user, which is essentially the purpose of downhill
racing
• whilst the removable and washable Coolmax liner wicks moisture away and
• Customisation is unique for every user. Professionals
keeps heat to a minimum
tend to have hand painted shells based on their own
• Waterproof, therefore it is easy to clean drawings, meaning that ordinary buyers can order a
Antonio Leiva takes
• Vinyls can be applied easily replica or go for a default company design. However,
the stairs
stickers made from 1mm vinyl can be purchased from
Components, the company, or from a mountain biking magazine or
shop (or any other sticker) and placed on where ever
• FHVS (Full helmet venting system) helps
desired
keep a constant airflow for heat management, without compensating for off road safety • The shell is made from a desired mixture of carbon
by having venting holes fibre weave mesh placed within a fibreglass shell
• Galvanised steel mesh across vent holes, which gives good corrosion resistance and • All of the components need to be anthropometrically
durability suited to a human head
• EPS and EPP foam inner liner conforms to users head shape, creating a custom fit, • Shell is lacquered after it has been painted, to protect
making it safer as it won’t be loose during use the finish and make the shell more durable. It also
adds to the aesthetics
• A movable visor is attached
Function:
• An air filter is positioned in front of the mouth
• To protect the user’s entire head from
• Aluminium screws and bolts for attachment of visor
primarily a single blow to the head
• ABS nut/ tightener for adjustment of pitch for the visor followed by smaller more general
• Steel buckle system for fixing in place on users head blows from all angles
• Synthetic leather for chin strap • To look aesthetically pleasing in
terms of design of shape and
• Aluminium rivets
effectively sales based on
• Nylon tag on buckle system, for ease of finding the buckle an also a safety feature if professional users wearing it
user has had an accident and someone else needs to find the buckle to remove the
• To be suited to players of all ages
helmet
(in terms of head size and shape)
• Air filter needs to keep the users
airway completely clear
• Whilst having a long life
• Being easy to replace
EPP foam helmet mould • Act as a shock absorber by
creating flexibility in the front
of the helmet, which acts
similarly to a crumple zone
Me wearing the helmet, showing the different angles of fit

6. Product Specification: 661 2011 Evo
Carbon Full Face Downhill/ Off-road
Bike Helmet
User Requirements: Scale of Production and
• Needs to protect the head from blows from all angles, Cost:
which would consequent in severe head injury or The general components of the helmet
concussion
Performance Requirements: (i.e. the shell) need to be mass
• To feel comfortable produced to comply with the high
• FHVS (Full helmet venting system)
demand. However, this isn’t possible for
• To be affordable
• Must keep a constant airflow for heat management, without all components
• Needs to fit typical head sizes compensating for off road safety by having venting holes • Shell-
• Needs o be light and partially flexible, without • Galvanised steel mesh • Carbon fibre mesh, needs to be
compensating for strength placed on a mass produced mould
• Must prevent foreign objects entering the helmet, with
and shaped by hand on a
• To feel fully custom with a unique look compensating the airflow
production line, to get the perfect Process flow diagram for the
• must be able to withstand long term usage shape (no dents e.t.c.) and to keep moulding process of carbon fibre
up with demand
• EPS and EPP foam inner liner
• Fibreglass Exterior, is vacuum
• Must conform to most head sizes, without being loose formed over the carbon fibre base
• Must be able to be cleaned easily and joined with a thermosetting
resin, placed in between
• Visor
• Aesthetics, Lacquer is sprayed by
• Must be able to block Sunlight, dirt and other foreign objects, machines, with
which would impair the users vision
• Must not break easily on impact with other objects
Diagram of formation
• Must be able to be adjusted for all user preferences of carbon fibre layers
A small selection of different • Air Filter
design schemes for the helmet • Must purify the air from dust and insects before it reaches the
Manufacture:
user Ben Byoko goes down hard
• The shell/ visor is made by hand
• Must be easy to replace after three attempts off a 22
foot drop in Saalbach 2006 • The carbon fibre mesh is coated
• Aluminium screws and bolts
after winning the qualifier in resin, which is then placed on
• Must not shear from blows which could potentially pull the shel a mould of the helmet in several
off, exposing the user’s head layers, offset at 60o
• ABS nut/ tightener for adjustment of pitch for the visor • It is then layered with more
• Must keep visor in a secure position mesh as required
• It is the placed in an oven to ....
• Must not break from pressure or knocks
• It is then coated in a similar
• Steel buckle system for fixing in place on users head
way, but with fibreglass
Why these helmets are • Must secure helmet to user’s head
• It is then hand painted or
useful... • Synthetic leather
robotically painted depending on
• Must not scuff easily design and lacquered for added
durability and strength
• Aluminium rivets
• Galvanised steel mesh is made with
• Must keep vital safety features in place (e.g. the chin strap, the
extruded steel wire, which is then
interior padding and the shell itself)
galvanised in...
• Nylon tag
• Aluminium fixings are machined by a
• To help user find buckle system and also for emergency help to CNC lathe
take hemet off easily
• EPS and EPP Foam

7. Form Function User Requirements
Schutt Ion 4D 661 2011 EVO Carbon Schutt Ion 4D 661 2011 EVO Carbon Schutt Ion 4D 661 2011 EVO Carbon
Evaluation: Compare and Contrast
• Shape • Shape • Face • Face • Price • Price
- Aggressive and warrior like - Elegant and smooth - Face cage needs to block - Air filter needs to be easy - £210 - £280 - £120
• Shell • Shell
players hands from to replace • Face cage • Visor
- Polycarbonate alloy - Hand crafted carbon fibre and
- mass produced by injection fibreglass on production line entering facial area - Needs to keep air way - Needs to be easy to - Needs to be adjustable
moulding • Finish - Face cage needs to absorb clear remove in an injury without slipping
• Finish - Hand painted or machine impact - Needs to act as a shock • Maximum range of visibility • Wide range of “cool” and
- Full graphical customisation painted - Field of vision needs to be absorber (like a crumple • Full customisation unique designs
- Protective lacquer - Protective lacquer at a maximum zone on a car)
Both helmets perform fairly evenly as the Ion 4D can be made The Schutt Ion 4D edges slightly ahead of the EVO. They both are The Evo Carbon out performs the Ion 4D in price as it is far more
quickly on a large scale because it involves a production line and designed to do the same thing. However, the ION 4D is much affordable. Customisation is not an issue as it can look just as
mass production. The Evo Carbon falls short here as it takes lighter and comprises of less material, but actually does a better good as the customisation of the Ion 4D, even with more finesse.
manual labour and time to create each individual shell of carbon job of absorbing the force of impact than the EVO. This is However, the Ion 4D does have a wider field of view, meaning
fibre. However, the EVOs customisation has more finesse than because the face cage itself is capable of flexing and coupled the user can see more of their surroundings. The EVO therefore
the ION 4D, mainly because the ION 4D has to compensate for with the energy wedge it outperforms the single shell of the EVO. can be quite limiting when looking for safer routes and obstacles
extended durability of the graphics and vinyls Also, the field of vision is roughly 50o more the EVO when on a bike.
Performance Requirements Materials and Components Scale of Production
Schutt Ion 4D 661 2011 EVO Carbon Schutt Ion 4D 661 2011 EVO Carbon Schutt Ion 4D 661 2011 EVO Carbon
• Must not crack after impact • Must be able to crumple and bend • The components of the helmet • The interior and general setup • Batch - for fully customised • One off - for custom designs
• Components must have minimal to reduce force of impact without are patented for Schutt use only of the helmet have been the bulk team orders for professional users
movement for user comfort injuring the user (in terms of use in american same for the last decade. The • Mass - for standard helmets • Mass - for general designs
• Must be well ventilated without • Must have good airflow and football). This makes them exception to this is the brand
compensating protection ventilation to prevent overheating and types of face cage for • Batch - for clients who want
unique and allows for the new exterior carbon shell individual resale to have replica designs used
• General comfort must be and allowing the user to breathe
advancement of concussion design and minor
maintained without high normally and feel comfortable by professionals
maintenance • Visor must stay secure reduction technology (e.g. TPU advancements in the EPS to
and the energy wedge) reduce head injury
Both helmets again perform well. However, the EVO can get very The Ion 4D has been a minor breakthrough in terms of reducing the number of The range of designs for both helmets are near limitless.
hot and stuffy after a long use causing great discomfort. However, concussions gained by a player in a season. However, it has not reduced the However, the EVO has the capability of being completely
number to guarantee complete safety and also there are other helmets on the
this can happen in hot weather with the Ion 4D as the sweat can get customised in terms of aesthetics. The Ion 4D can have custom
market who are also very upstanding in the market (Xenith X1 and 2 with the )
trapped on the air liner. The Evo can be a hassle in the long run due and future designs which have the potential to do better. The Evo may not be logos, but it is restricted to only these logos and single or set
to its design to crumple slightly on impact, therefore needing to be made of huge technological advancements, but for its purpose of single impact patterned colour schemes. This allows the EVO to be produced
replaced. The Ion on the other hand can be used consistently for 2 use it has been beneficial for saving hundreds of lives in many serious crashes on a wider range of production scales for different purposes.
years, with the recommendation for it to be reconditioned after. and falls on varying terrain.
Both helmets perform extremely well in their environments. However, the American football helmet is generally the better of the two helmets. My
main reason for saying this is because american football helmets in general are designed to take repeated impacts . Downhill bike helmets are
designed to absorb high impact energies once. They do this through use of a combination of EPP and EPS - materials that crack and bend to slow
down acceleration of the head upon impact. A football helmet, in contrast, needs to absorb high impact energies on a multitude of hits (sometimes
on the same play) over a period of several years. So if you drop the bike helmet, the manufactures' label often states that the helmet should be
discarded or sent back into the manufacturer to give it the once over, but they don’t get refinished. A football helmet, on the other hand, is sent in
for reconditioning every two years and is completely repainted and finished so it comes back to the user as if like new.

8. Team Helmets and kit
A view from all sides
A view from all sides
Lining up on the scrimmage
Helmet in use A front view with visor
Team helmets in play blocking sun on a sunny day
Helmet absorbing impact on
ground, therefore protecting my
head and neck from serious
How the helmet prevented me
breaking my neck vertebrae by injury
stopping my neck going over itself

9. Quality Control:
Injection Moulding of the Shell Start
NO?
Yes? Finish
Start
Form Mould
Initial Designs
NO?
NO?
Check for
Evaluate the Check that the measurements correct in structural defects, which will impact on
suitability of each design and choose the relation to the final design quality of product, in terms of shape
final design and finish e.t.c.
Injection Moulding
NO?
Yes? Yes? Yes?
Draw final design
Coat inside of mould with Check the quality of the
Mould Design
NO? water based lubricant mould
Check all relevant detail NO?
is present and that it will work with the
moulding process
Check that an
Check the quality of the
even layer has been applied to the entire
product (i.e. the shape, the finish, structural
mould and that it has not been used to
Yes? defects, e.t.c.)
an excess
Input the design into CAD NO?
Yes? Yes?
NO?
Close the two halves of the
Eject the Product
Check dimensions are mould together
correct and then create a contour line for
tolerance when milled
NO?
Yes? Check the pressure is Check whether it has reached a
sufficient enough to keep a tight seal and have no reasonable temperature to eject from the mould
Export to CNC Milling Machine leaks
NO? NO?
Yes? Yes?
When cut, check
dimensions with a computerised probe Feed pellets of the specified
sensor polycarbonate alloy into the hopper
Allow the product to cool
Yes?
NO?
Finish the mould with various tools
(i.e. Emery cloth, water jets) Check that all
of the pellets have been melted into a
NO? consistent liquid and that the temperature Check that the die is full
is correct
Check that there are no defective cracks
NO?
with an ultrasound machine
Yes?
Allow the hydraulic ram to push the
molten polycarbonate into the mould
cavity via the sprue
Start

10. Quality Control: Main Quality Standards
Identification and description on main quality standards:
Injection Moulding of the Shell BS EN 201:2009
Injection moulding, Moulding (process), Moulding equipment,
Plastics and rubber technology, Plastics, Plastics-working
machinery, Rubber, Occupational safety, Equipment safety,
Raw Material: Hazards, Electrical safety, Accident prevention, Noise
Documentation of the following should be provided with the granules of the (environmental), Gases, Dust, Machine guards, Interlocks,
Polycarbonate to be used: Safety devices, Safety measures, Temperature-rise limit,
• Quantity Clamps (mechanical), Anthropometric characteristics,
• Size Instructions for use, Verification, Test equipment.
• Properties (i.e malleability or flammability)
• Testing results (i.e thermal expansion value, the shrinkage value and the impact BS EN ISO 10724-1:2001
strength) Plastics, Injection moulding, Particulate materials,
• Information to show that the product adheres to national standards such as the Thermosetting polymers, Test specimens, Moulding (process),
CE mark or the Kite mark. Plastics and rubber technology, Specimen preparation,
Sampling methods, Moulding equipment, Testing conditions,
Tooling: Equations, Volume, Area, Dimensions, Shape, Melting point,
CMM and computerised optical equipment is used to make sure that the injection Stages of the Temperature measurement, Marking, Moulding compounds.
moulding machine mould is 100% dimensionally correct. This is to-
• Make sure that the shell is the right size and shape for the other components to mould itself BS EN ISO 10724-2:2001
fit together with Plastics, Injection moulding, Particulate materials,
• The structure of the shell itself is will not be impaired and made defective, Thermosetting polymers, Test specimens, Moulding (process),
therefore endangering the user when used Moulding compounds, Plastics and rubber technology, Size,
• To make sure it is durable enough to withstand constant use for mass production Shape, Thickness, Preferred sizes, Dimensions, Test
• To make sure it allows the product to be ejected quickly and easily without equipment, Volume, Specimen preparation, Welded joints,
distortion (in terms of heat dissipation and intake) Tensile testing, Mechanical testing, Marking.
• To produce a perfectly smooth finish, so that minimal manual input is needed to
finish each helmet before assembly The influence of quality standards during the production
Heated Polycarbonate Alloy: BS EN 201:2009
The polycarbonate alloy needs to be consistently monitored. This is in order to The injection moulding press, equipment and plastics used
primarily control the fluidity of the molten material. However, it is also for the must adhere to this BSI standard. Also, the method in which
following- the product is manufactured is affected in the sense that
• To make sure that it is heated up only for the needed time. This stops the manufactures carrying out the work must wear dust masks as
fossil fuels used to heat it up to be wasted well as being protected against loud noises.
• To make sure the production time is efficient to gain the maximum possible
turnover (i.e. if the alloy is overheated it will take longer to cool down, BS EN ISO 10724-1:2001
therefore increasing the production time) This quality standard means that when testing the
• To prevent the alloy becoming deformed and losing its required properties to thermosetting polymers used in injection moulding the
withstand high impacts and absorb them manufacturer should adhere to specific test equipment,
• To measure the before and after temperatures to prevent the product being including the equipment used for testing, volume of product
removed prematurely being tested, thickness of product and other sizing
that it is not removed prematurely. specifications.
Finished Mould: BS EN ISO 10724-2:2001
When the shell has cooled, it has to be inspected- This is where manufactures must adhere to using specific
• Visual, The finished product of materials whilst testing, as well as only being allowed to
• For quality of finish, excess flash/ roughness use certain volumes, sizes and tensile values whilst
• Structural defects, cracks the injection moulding testing. Also, the equipment used for testing must have
• Shape defects, dimples/sink marks particular welded joints.
process
• Computerised and other electronic methods,
• Ultrasound, to for any microscopic cracks, which would impair the
performance of the shell
• Dimensions of the helmet are measured by a machine Granules of a
• The weight is measure to the nearest 100th of a gram within 0.05mm of
the specified weight, so that the players neck is not harmed polycarbonate
alloy
A typical
injection Injection
moulding moulding
machine machine
components

11. Batch Production:
A single production line can be used to produce a range of
components which will be manually assembled at the end of
production, to form the helmet. Batch production will offer
versatility in making a certain number of helmets to a
particular specification for example: the vinyl/graphics, face
cage and colour. It allows for the customisation of an order of
helmets to make them exactly the same, without the adjustment
Scale of Production
of machines in between.
Advantages of Batch Production:
Batch production can reduce the initial capital outlay because
a single production line can be used to produce nearly every
single product as the only variations on the product are colour
(as face cages are a separate order) and size, meaning the
interior and attachment systems (bolts and chin strap e.t.c.)
are exactly the same so the labourers on the production line
just have to fit their assigned component to every helmet that
passes them. If a retailer buys a batch of the product and they
don’t sell, then Schutt can adjust their production levels
accordingly.
Batch production is also useful for the factory as the helmets
can sell more seasonally. This makes it harder for the
manufacturer to forecast the demand as peoples habits can
change easily, for example a different sport may become more
popular so no less helmets are needed or the NFL may brand
Schutt as the official helmet manufacturer for the league
instead of Riddell. However, the general theme is that more
helmets sell during the winter as it is most players pre season
or actual season and also the NFL season is occurring. Batch
production is also useful for trial runs of new designs
(usually to a very small number of people initially for safety
reasons) and for products that have a high profit margin and
therefore the number of products needed to be produced
adjusted.
Disadvantages of Batch Production:
Batch production also has disadvantages. There are
inefficiencies associated with batch production as equipment
must be stopped, re-configured, and its output tested before
the next batch can be produced. This idle time between batches
is known as downtime. This has to occur because of the high

12. Quality Assessments- Safety Standards Schutt Ion 4D 661 2011 Evo Carbon
NOCSAE: The National Operating Committee on Standards for CPSC- The U.S. Consumer Product Safety Commission is
Athletic Equipment (NOCSAE) is the absolute necessity for an charged with protecting the public from unreasonable risks of
american football helmet to be allowed to be sold and used. injury or death from thousands of types of consumer products
Helmets selected to be tested (about 3 from a batch of 50) are under the agency's jurisdiction. The CPSC is committed to
mounted on an instrumented head model (similar to that of a protecting consumers and families from products that pose a
crash dummy) and tested with various drop and impact tests fire, electrical, chemical, or mechanical hazard or can injure
(reproducing real life situations) before and after reconditioning children. The CPSC's work to ensure the safety of consumer
in accordance with the NOCSAE Standard and NAERA By- products - such as toys, power tools, cigarette lighters, and
Laws. The testing includes various impact energies, standard and household chemicals. It has contributed significantly to the 30
random locations under controlled environmental conditions. percent decline in the rate of deaths and injuries associated with
Acceleration measurements are taken to determine if the helmet consumer products over the past 30 years.
meets an established Severity Index (SI) requirement. SI is a CE: 1078- The letters "CE" are the abbreviation of French phrase
scientifically accepted measurement of human injury tolerance. "Conformité Européene" which means "European Conformity." CE
Some required impacts are equivalent to running in excess of 12 Marking is now used in all EU Products that are legally sold.
1. CE Marking on a product is a manufacturer's declaration that the
MPH into a flat surface, which stops a player’s head suddenly.
product complies with the essential requirements of the relevant
Some players run faster than this (the fastest being Tennessee
European health, safety and environmental protection legislation.
Titans Wide Receiver Chris Johnson at over 26 mph) but seldom 2. *Product Directives contains the "essential requirements" and/or
if ever experience an impact as violent as the NOCSAE test. The "performance levels" and "Harmonized Standards" to which the
test covers a variety of tests, which have to be passed in order to products must conform. Harmonized Standards are the technical
be awarded the official seal. The NOCSAE covers all of the specifications (European Standards or Harmonization
Documents) which are established by several European standards
safety tests and requirements that would have to be individually
agencies (CEN, CENELEC, etc). CEN stands for European
certified in the EU.
Committee for Standardization. CENELEC stands for European
ASTM- The American Society for Testing of Materials (ASTM) Committee for Electrotechnical Standardization.
is the American equivalent of the British Standards Institute 3. CE Marking on a product indicates to governmental officials that
the product may be legally placed on the market in their country.
(BSI). It has since become an international standards agency
4. CE Marking on a product ensures the free movement of the
that is used as an alternative to the BSI. Originally a voluntary
product within the EFTA & European Union (EU) single market
standard, an ASTM certification now has been endorsed by the (total 28 countries), and CE Marking on a product permits the
American government and the National Football League (NFL) as withdrawal of the non-conforming products by customs and
a recognisable certification, required nationally for products enforcement/vigilance authorities.
designed to be used as safety equipment. the ASTM does not The number (1078) indicates the type of test used. In this case it is one of
the toughest in the world, where various high impact and durability tests
always carry the test out itself, but instead acts as a moderator
are used on each component of the helmet.
to make sure that the product actually deserves the certification
of being “safe.” AS/NZS 2063- AS/NZS stands for the Australian/New zealand
standard. Again this is basically the health and safety standard
required for a product to be sold in these countries. The number
also relates to the test used to certify the product for sale.

13. Preparation: Processing:
The polycarbonate alloy will be checked QC inspectors take random samples of
for correct expansion and shrinkage helmet shells pieces at certain time
value as well as looking for the intervals (about 3-5 per batch) and
correct impact strength and tensile check to ensure that they meet set
strength values. Batches for non- specifications for size, shape, and
professional teams in particular will consistency (using veneer callipers
have their colour checked, as they will and other gauges) The colour can be
not be manually painted and detailed, checked for consistency, shade, style
therefore the colour must be accurate and also that it does not run or rub
for the given order. off the shell by touch.
Assembly:
During assembly (done by hand on a production line)
each part is reinspected visually for flash or
other visual and safety impeding deformities on the
helmet shell. Also, for each batch every single
custom part is visually inspected for design,
colour, decals/ vinyl logos and finish according to
an order to make sure that a batch all look the
same and that they are what the client has
customised their order to.
Finishing:
After shells have been manually fitted with
interior components and attachment systems,
they are packed in bubble wrap and paper thin
foam and placed in boxes only just bigger
than the helmet. A small helmet pump and
nozzle lubricant for the inflatable bladders,
a warranty pamphlet and Manual for fitting to
a users head and how to get the helmet
reconditioned over time and both the hard and After-sales:
soft chin cup options are also placed in the The product is given a guarantee of at least
box. Batch orders are then placed into larger one full season or either a replacement or
boxes and moved to a separate part of the money back offer is given to the client.
factory to be shipped via a logistics company
This is due to the high safety requirement
to the individual user or the teams club. The
other basic one colour helmets are then and the importance of the players safety.
shipped in a similar way, but in larger, For team orders a discount is offered and
mixed batches to be resold by a company/ team customisation is available.
business who specialise in sport. In order
for the helmets to reach the correct
destination,

14. Analysis: Components - Cross Section

15. Analysis: Components - Interior
Safety Standards and
Note: Skydex is the
disclaimers
manufacturer of TPU
Cushioning

16. Analysis: Components - Additional
Information and Statistics
The manufacturer’s official
description for the individual
components
Further detail of the smaller
components

17. Analysis: Component breakdown
TPU Cushioning
Product
The Overall
TPU Jaw Pads