Revolutionizing Helmet Design: Fast Study and Shape Optimization with DEP MeshWorks
2024 International LS-DYNA Conference, Metro Detroit, Michigan, USA - A. Leglise, A. Guilpin, C. Michel, V. Lapoujade, M. Seulin (Dynas+ Engineering Products)
Abstract
In the sports and security industries, helmets must meet strict safety criteria across various sizes and configurations. This study showcases how DEP MeshWorks, in conjunction with LS-DYNA and LS-OPT, enables faster product development cycles and design optimization. Using advanced morphing and mapping technologies, DEP MeshWorks reduces meshing time by up to 70%, ensuring compliance with safety standards while delivering optimal performance.
Key Results from the Study
- Objective: Streamline helmet design for multiple sizes and optimize safety and performance.
- Challenges Addressed:
- Time-consuming manual meshing for each helmet size.
- Need for iterative design modifications to meet safety standards.
- Technological Advantages:
- DEP MeshWorks’ morphing and mapping tools reduced meshing time by 70%.
- LS-OPT facilitated parameterized optimization for weight reduction and safety compliance.
- Real-World Impact:
- Demonstrated success with DECATHLON, achieving a 70% reduction in development time for helmet design.
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How DEP MeshWorks Transforms Helmet Design
- Innovative Processes:
- Morphing capabilities used to adapt finite element models to different sizes without remeshing.
- Automated mapping tools for creating high-quality meshes across helmet families.
- Impact Analysis:
- LS-DYNA simulations tested various impact points and configurations.
- Optimization using LS-OPT ensured compliance with acceleration and foam thickness criteria.
- Time Savings:
- Traditional helmet meshing reduced from 3 days to 3 hours using DEP MeshWorks.
- Reduced helmet meshing time by 70%.
- Streamlined development cycles from 110 days to just 30 days.
- Optimization Results:
- Improved foam thickness compliance for smaller helmet sizes.
- Mass reduction while meeting safety standards.
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Scaling Innovation across Industries
This methodology not only enhances helmet design but also extends to other product families requiring multiple sizes, such as consumer goods. For example, DECATHLON achieved a 70% reduction in development time using DEP MeshWorks, underscoring its transformative potential across various applications.
This study highlights the power of DEP MeshWorks, LS-DYNA, and LS-OPT in accelerating product development cycles while ensuring compliance with rigorous safety standards. By leveraging advanced morphing, mapping, and optimization tools, engineers can explore designs more efficiently, enabling cost savings and performance improvements across industries.
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