3D printed padding systems are improving bomb disposal safety wear, with companies like Rapid Product Manufacturing engineering foam alternatives for helmets that help operatives keep their cool
Explosive Ordnance Disposal (EOD) helmets are key to a bomb disposal technician’s PPE. As well as a hard outer protective shell, internal padding plays a key role in energy absorption, comfort in a high-stress environment and a secure fit.
To take this design further, Rapid Product Manufacturing (RPM) designed a new, lighter and safer internal padding system.
The new open-cell internal lattice replaces traditional foam padding, with the honeycomb-like structure being lighter and more comfortable for the wearer.
The lattice geometry means that stiffness and damping can be locally modified, so that different areas of the head can be protected individually. EOD helmets are often worn for prolonged periods of time, and the open structure of the lattice allows for ventilation and simplifies cleaning.
The design uses less material than traditional foam, allowing for reduced weight while not compromising on protective performance.
The design, material selection and manufacturing parameters were carefully chosen to ensure consistent serial production on 3D printing systems from Farsoon.
When it comes to PPE, quality assurance and regulation are essential to keeping personnel safe. EOD helmets must undergo rigorous testing for fragmentation, blast overpressure, impact and heat.
Hamburg, Germany-based quality assurance software provider Amsight were entrusted to oversee processes and part data across the entire manufacturing chain, identifying any issues or quality defects in the helmets’ lattice before they occurred.
Data evaluation – including statistical process control, material behaviour, process parameters and component properties – was provided by Amsight to document and provide traceability of the manufacture, feeding back data to better optimise the design.
With the new lattice design responsibly removing weight and increasing airflow, EOD operatives should be cooler in even the most stressful situations.
