Gyroid protective helmet shell - 3D printed foam

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Problems of most USED - EPS (expanded polystyrene) based foam helmet shellS:

SAFETY MISCONCEPTION - Although protective helmets with EPS foam shells look undamaged after crash, they are single use, because EPS tends to crack or compress without recovery, becoming unsafe.

WASTE - As EPS is already overwhelmingly used as protective packaging material, its highly ranked polluter. Its toxic to human and environment, and challenging to recycle even if we dispose it properly because its prone to easly break into microparticles.

COMFORT - EPS is great thermal insulator, because of micro pockets that traps air, but its not porous thus not offering sufficient breathability that might be important during intense activities.

WhAT IS Gyroid? How is it related to 3D printing?

Gyroid is porous, lightweight and advanced microstructure found in sea-urchin skeleton and butterfly wings. It features no joints or discontinuities allowing great unified air and liquid permeability and distributing stress concentration equally in all directions.

Because of its complexity, without Additive Manufacturing technology (3D printing) it was nearly impossible to recreate such structure. Although the full potential of TPMS* Gyroid structure is not entirely revealed to public, we are witnessing many benefits and spectrum of its applications, but its most commonly used as infill structure in 3D printing because:

1. It is an almost isotropic structure, which means that it is equally resistant to forces coming from all directions.

2. Doesn't need supports - TPMS structures are self-supporting in nature, making them perfect especially for FDM (extrusion based) manufacturing.

3. Gyroid's weight is highly reduced - eg. 30% lighter than honeycombs

4. Less material consumption with better performance

5. Shorter printing times

6. Great liquid and air flow - its porosity allows unified distribution in all directions

3D printing as revolutionary technology amongst many benefits allowed us widespread accessibility, waste reduction and ability to personalize our everyday objects faster at reduced cost.

*TPMS - triply periodic minimal surface

Credits to @WildRoseBuilds for gyroid 3d printing timelapse

Isometric and Front view showing porosity of TPMS Gyroid structure (Walled and Full)

DIGITAL FOAM?

Digital foam is "preprogrammed" flexible material, optimized for best performance.

Name is coined by EOS GmbH company. It is dedicated for 3D printing and mass customization which stands for serial production of end-use products adjusted for each individual.

"Digital foam found its way into 3D printing. It allows flexible material to be precisely adjusted and manufacture more comfortable, safer and lighter products that can be individually customized." - EOS GmbH, https://www.eos.info/en/innovations/think-hub/digital-foam

With help of new generation engineering software such as nTopology, I was able to variably adjust flexible material properties by combining various types, sizes, densities and thicknesses of gyroid structures with smooth geometry transitions. Those properties can significantly reflect on product performance, comfort and safety.

One product from one process, one material with infinite possibilities.