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Table of contents
1 INTRODUCTION
1.1 BACKGROUND
1.2 PURPOSE
1.2.1 Deliverables
1.2.2 Delimitations
2 METHODS
2.1 ITERATIVE DESIGN PROCESS
2.2 PROJECT PLANNING METHODS
2.2.1 Project plan
2.2.2 GANTT-chart
2.3 INFORMATION RETRIEVAL
2.4 COMPETITOR ANALYSIS
2.5 MATERIAL ANALYSIS
2.6 SEMI-STRUCTURED INTERVIEWS
2.7 IDEATION WORKSHOP
2.8 FOCUS GROUP
2.9 IDEATION
2.9.1 Brainstorming
2.9.2 Moodboard
2.9.3 Speed sketching
2.9.4 Exploratory sketching
2.10 EVALUATION
2.10.1 Pugh-matrix
2.10.2 SWOT-analysis
2.10.3 Clay model
2.10.4 CAD
2.10.5 Physical prototype
3 FRAME OF REFERENCE
3.1 PROJECT PLAN
3.2 USER GROUPS
3.2.1 SAR
3.2.2 SSRS
3.3 ERGONOMICS
3.3.1 Head sizes
3.3.2 MIPS
3.4 ESSENTIAL HELMET COMPONENTS
3.4.1 Outer shell
3.4.2 Inner liner
3.4.3 Comfort liner
3.4.4 Chinstrap
3.4.5 Retention system
3.5 EXTERNAL COMPONENTS
3.5.1 Communication
3.5.2 Eye protection
3.5.3 Camera
3.5.4 Snorkel
3.6 STANDARDS
3.6.1 Helmet standards
3.6.1.1 PAS 028
3.6.1.2 Testing according to PAS 028
3.6.2 Component standards
3.7 COMPETITOR ANALYSIS
3.7.1 Main competitors
3.7.1.1 Predator
3.7.1.2 Gecko
3.7.1.3 Manta Hi-Viz SAR Multi-Role Helmet
3.7.1.4 OPS-core FAST
3.8 MATERIALS
3.8.1 Outer shell
3.8.1.1 Composite shell
3.8.1.2 ABS
3.8.1.3 PC
3.8.2 Inner liner
3.8.2.1 EPS
3.8.2.2 EPP
3.8.2.3 EVA
3.8.3 Inner liner and shell combination
3.9 MANUFACTURING
3.9.1 Injection moulding
3.9.2 Thermoforming
3.9.2.1 Vacuum forming
3.9.2.2 Pressure forming
3.9.2.3 Design recommendations
3.9.3 Expanded foam moulding
3.10 ASSEMBLY METHODS
3.10.1 Spray Adhesive
3.10.1.1 Double-sided adhesive
3.10.1.2 Two component glue
3.10.2 Fasteners
3.10.3 External components
3.10.3.1 ACH-ARC rail
3.10.3.2 Picatinny Mount
3.10.3.3 Commercial mounts
4 IMPLEMENTATION
4.1 EVALUATION OF Y1
4.1.1 Workshop with SAR
4.1.2 Workshop with SSRS
4.1.3 SWOT-analysis of Y1
4.2 DESIGN REQUIREMENTS
4.2.1 Interview with Mikael Swarén
4.2.2 Inner liner thickness
4.3 MATERIAL ANALYSIS
4.3.1 Material requirements
4.3.2 Benchmarking
4.3.3 Material sample droptest
4.3.3.1 Droptest
4.4 CONCEPT GENERATION
4.4.1 Brainstorming
4.4.2 Moodboards
4.4.3 Speed sketching
4.4.4 Exploratory sketching
4.4.5 Feedback from HOWL design studio
4.5 FURTHER DEVELOPMENT
4.5.1 Refined sketching
4.5.2 Mount concepts
4.6 PROTOTYPING
4.6.1 Clay models
4.6.2 Digital prototypes
4.6.2.1 Form
4.6.2.2 Function – carrier of systems
4.6.2.3 Materials and manufacturing
4.7 CONCEPT EVALUATION
4.7.1 SAR
4.7.2 SSRS
4.7.3 HOWL
4.7.4 Baering
4.7.5 Concept evaluation
4.8 FURTHER REFINEMENT
4.8.1 Mount concept
4.8.1.1 Flush ACH-ARC rail
4.8.1.2 Picatinny snap mount
4.8.1.3 Flexi snap mount
4.8.1.4 Mount Evaluation
4.9 MIPS
4.10 PRODUCTION R1 HELMET
4.10.1.1 Manufacturing process
4.10.1.2 Injection moulding
4.10.1.3 Thermoforming
5 RESULTS
5.1 R1 – RESCUE ONE HELMET
5.1.1 Ergonomics
5.1.2 Standards
5.2 HELMET COMPONENTS
5.2.1 Outer shell
5.2.2 Inner liner
5.2.3 Ear covers and chin strap
5.2.4 Communication system
5.2.5 Retention system
5.2.6 Mount concept
5.2.7 Half integrated top light
5.2.8 Eye shield
5.2.9 Visor concept
5.3 PHYSICAL PROTOTYPE
5.3.1 Outer shell
5.3.1.1 Milling
5.3.1.2 Vacuum forming
5.3.2 Liners
5.3.3 Mounts
5.3.4 Assembly
5.3.5 Estimated cost calculation
5.4 TESTING
5.4.1 Testing at MIPS
5.4.1.1 Testing
6 DISCUSSION AND CONCLUSIONS
6.1 PROCESS
6.2 Y1 EVALUATION
6.3 USER CENTRED DESIGN
6.4 MATERIAL CHOICE
6.5 MANUFACTURING
6.6 PHYSICAL TESTING
6.7 FINAL RESULT
7 RECOMMENDATIONS AND FUTURE WORK
7.1 POTENTIAL MANUFACTURERS
7.2 MOUNT TESTING
7.3 INITIAL EVALUATION
7.4 FURTHER TESTING
7.5 FIELD TESTING
7.6 REFINE DESIGN
7.7 FINAL EVALUATION
7.8 CERTIFICATION AND MANUFACTURING
8 REFERENCES
9 APPENDIX
APPENDIX A – PROJECT PLAN
APPENDIX B – GANTT-SCHEME
APPENDIX C – FOLKSAM HELMET TEST RESULTS
APPENDIX D – STANDARD EVALUATION
APPENDIX E – TEST METHOD DESCRIPTION
APPENDIX F – COMPETITOR ANALYSIS
APPENDIX G – JENS ARPRO, SUGGESTED ADHESIVES
APPENDIX H – WORKSHOP SAR, Y1 EVALUATION
APPENDIX I – DESIGN GUIDELINE
APPENDIX J – INTERVIEW MIKAEL SWAREN
APPENDIX K – MATERIAL PROPERTIES
APPENDIX L – MATERIAL BENCHMARK
APPENDIX M – UNDERLAY
APPENDIX N – HOWL MEETING
APPENDIX O – SAR CONCEPT EVALUATION
APPENDIX P – HOWL CONCEPT EVALUATION
APPENDIX Q – COMPANIES CONTACTED
APPENDIX R – THERMOFORMING GUIDE
APPENDIX S – MIPS TEST PLAN
APPENDIX T – MIPS TEST RESULTS
