A Precision Method for Integrating Shock Sensors in the Lining of Sports Helmets by Additive Manufacturing

A method is presented for embedding sensors into the lining of sports helmets for the purpose of monitoring head impact in contact sports. Additive manufacturing was used to embed optical fiber-based pressure sensors inside thermoplastic polyurethane (TPU), a material used for lining and shock-dampening that fills the space between a helmet's hard outer shell and the head. A proof-of-concept has successfully demonstrated sensitive shock-monitoring capabilities, thus avoiding the inaccuracies in existing systems. The sensors can be embedded into additively manufactured parts in new or existing helmets and are unobtrusive to the wearers. This proposed system can be powered by readily available medical-grade cell batteries and requires less maintenance.