Development and impact characterization of acrylic thermoplastic composite bicycle helmet shell with improved safety and performance

Fiber-reinforced composites are increasingly used as an outer shell of sporting helmets alternative to conventional thermoplastic shells like Acrylonitrile butadiene styrene (ABS), Polyurethane (PU), and polycarbonate (PC) for improved protection. The current research presents a detailed study manufacture novel woven carbon/Elium® (WEL) composite investigate the details based on impact tests following industrial safety certification criteria (CPSC 1203 helmet certification) flat, curb-stone, hemispherical anvils. effect Elium® resin toughened IM, Epoxy is investigated understand benefits offered by variants in terms safety, energy absorption, failure mechanisms. Post-failed Carbon/Elium® have shown more ductile less catastrophic damage opposed Carbon/Epoxy damage. mechanisms observed from in-situ high-speed camera images deformation-dominated manufactured with resin. lower absorption nature was cracks were noticed inner side foam which directly attached human head. In case flat anvil, PC configuration has critical injury rate 28.7% fatality 6%. With helmets, chances fatal rates reduced 16.7% 3% respectively. • Manufacturing carbon Elium®, IM matrix. Impact test performed CPSC certification. All configurations passed peak acceleration <300G. Ductile absorption. Manufactured 3%.