KORK
Client
RMIT University
Location
Melbourne, Australia
Year
2022
Helmets are the main method of protection for motorcyclists and are critical for keeping riders safe in an accident. However, helmet recycling can be challenging due to its construction and manufacturing methods. It is generally recommended that motorcyclists replace their helmets every 5 years, but research has found that users may not always follow this advice. The goal of this project is to redesign helmet manufacturing with alternative, more sustainable materials, and to shift the current industry trends towards sustainability. Additionally, the National Plastics Plan in Australia aims to phase out Expanded Polystyrene (EPS) in loose fill and moulded consumer packaging in 2022. Using a circular economy approach, the design will utilize modularity to make it easier for consumers to repurpose used helmets and to send a message to manufacturers about the importance of sustainability. By utilizing design methodology and academic research, the project aims to analyse research findings and design and prototype a sustainable helmet.
Design & Sketches
To explore different forms of the helmet, I started by coming up with various options. With the main design process focusing on the material aspect of the helmet, I wanted to give a progressive redesign of the current helmet. The various styles of motorbike helmets, such as the open-face and close-face, made it difficult to choose a specific helmet to design. With fewer parts to manufacture and more time to focus on the design, I opted to design an open-face helmet for commuters, the intended target audience for the helmet. In the first sketch stages, I played around with different types of forms but soon realized that the overall shell must be fairly rounded to comply with safety standards.
Inner Core
To design the inner core of the helmet, I went through multiple iteration stages of CAD design on Fusion 360 to shape and modify the form of the helmet. Using FDM printing, I was able to print a physical replica of the design to see how the parts would interact before finalizing the design. The first couple of designs and 3D prints for the helmet were focused on the general form factor. I also explored how the helmet could be separated into sections, ultimately finding the best method to key the pieces together. As I wanted the inner core to be removable, I used the same design language as current helmets, allowing the pieces to key together once placed in the outer shell of the helmet. This also allowed for minimizing any adhesive use, as the design relied on a friction fit.
Final Design
Outer Core
Through my research, I found that injection moulding was the best production method. However, due to the cost involved in machining the parts for this process, I plan to use vacuum forming for my prototype instead. Polycarbonate, a thermoset plastic, can be heated and vac-formed to manufacture the helmet parts. One concern of the design process was to avoid overhangs on the part to facilitate the removal of the vacuum-formed "buck" once it has cooled. As most helmet designs have slight overhangs, I conducted testing to see if my helmet design could be manufactured using vacuum forming. I printed a 3D scaled form using an FDM printer and placed it in a vac former, with successful results allowing for the part to be removed.
Assembly
With the creation of the Kork helmet, I have put forth a set of ideas for a working business model. This includes the implementation of sustainability through servicing from the company to assess the helmet for wear and tear annually, and to replace any worn-out parts sustainably. The helmet will also include information about how to properly dispose of it at the end of its lifespan.