Engineering and design of a last mile novel helmet concept

Abstract

Modern society witnessed a remarkable surge in urban mobility with the proliferation of micro-mobility sharing services. However, this transformation has also led to a worrisome increase in severe accidents and injured users. In addition, conventional helmets are significantly lacking in sustainability. This research investigates the feasibility and safety aspects of a novel bicycle helmet concept using cork as a protective liner. In comparison to traditional synthetic foams, cork offers eco-friendly advantages, such as recyclability and superior protection against multiple impacts. The newly proposed helmet is designed to provide enhanced sustainability and convenience, maintaining compliance with the EN 1078:2012+A1 standard whilst offering the capability to flatten for easy storage and transportation. Numerical simulations were conducted to optimise the design concept, and impact tests, in accordance with the European standard, were performed using physical prototypes categorised into three types of design configuration. The results from the standard impact test were outstanding, with the best performing configuration demonstrating a performance 36.8% below the standard’s threshold. This falls within the average performance range of a regular bicycle helmet made entirely of petrol-derived materials. Furthermore, it exhibited safe head injury criterion levels, indicating a minimal risk of severe head injury.