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Testing helmets before selling is crucial because helmets are designed to protect users from serious head injuries, which can be caused by a wide range of activities such as sports, motorcycling, biking, and even construction work. Testing ensures that the helmet meets safety standards and provides adequate protection to the user in case of accidents or impacts.

Helmet testing typically involves subjecting the helmet to a series of impact tests, which simulate different types of crashes or accidents. These tests help to evaluate the helmet’s ability to absorb and distribute impact forces, as well as its ability to stay in place during an accident.

By testing helmets before selling them, manufacturers can ensure that the helmets meet the required safety standards and provide the level of protection needed to prevent serious injuries. This helps to protect both the users of the helmets, as well as the manufacturers from potential liability issues.

TABLE OF CONTENTS

• Industry Need
• Our Perspective
• Helmet Certifications
• Testing Criteria
• G-Load Requirements
• DFMEA with Twinmo AI
• Path to Commercialization

INDUSTRY NEED

Can you summarize the article at https://www.grainger.com/know-how/safety-health/ppe/kh-hard-hats-vs-safety-helmets by Grainger (who are they?) on hard hats vs safety helmets and how the industry is morphing to accommodate the underpinnings of Industry 4.0 to workers in manufacturing, construction and other areas where PPE is being mandated.

Sure! Here’s a summary of the article:

• Grainger, a leading distributor of industrial supplies and safety products, discusses the differences between traditional hard hats and safety helmets in their article.
• Hard hats, which have been used for decades, are designed to protect workers from falling objects and debris. However, they have limitations in terms of protection and comfort.
• Safety helmets, on the other hand, are a more modern and advanced form of head protection. They offer better protection against impacts, as well as improved comfort and adjustability.

The article notes that many industries, including manufacturing and construction, are moving towards safety helmets as the preferred form of head protection. This shift is driven in part by the need for greater protection in hazardous work environments, as well as the growing trend towards Industry 4.0, which emphasizes technology and automation in manufacturing.

Overall, Grainger suggests that safety helmets offer a more comprehensive and effective solution for head protection, and are likely to become the standard in many industries in the years to come.

OUR PERSPECTIVE

For over 100 years, hard hats have helped protect workers from various hazards, including falling objects, tools, debris and electrical hazards. However, the hard hat wasn’t designed to protect against injuries from slips, trips and falls, which in 2020 resulted in over 200,000 serious injuries that required days off work according to data from the National Safety Council’s Injury Facts.

Traditional helmets often lack the advanced features necessary to provide real-time monitoring and proactive protection. Without our solution, safety measures rely primarily on passive protection, such as sturdy construction and standard safety protocols. However, these methods may not adequately address dynamic hazards or provide timely alerts in emergency situations.

Our Smart Helmet addresses the critical issues of usability, safety and situational awareness across various industries and activities. Our product revolutionizes safety, usability, and operability by integrating cutting-edge technology – parametric modeling, generative design, additive manufacturing and mobile connectivity by including sensors for geo-location, vision, environmental monitoring, and motion detection. This comprehensive sensor suite enables constant monitoring of the wearer’s surroundings, allowing for early detection of potential hazards such as falling (often referred to as man-down situation), gas leaks, environmental risks, sudden movements indicative of accidents or monitoring quality control and operational conditions in manufacturing.

Whether it’s in industrial settings, outdoor recreational activities, emergency response scenarios, or home care, our Smart Helmet sets a new standard for safety, offering unmatched protection and peace of mind to users across various industries and activities.

HELMET CERTIFICATIONS

The specific regulations and certification requirements for industrial helmets, construction hats, and bicycle helmets vary depending on the country or region where the marketing and selling is done. It is important to consult the relevant regulatory authorities and standards organizations in your target market to ensure compliance.

Bicycle Helmets need to meet safety regulations governed by EN 1078 and CPSC standards. Can you describe these standards?

Certainly, let’s dive into these bicycle helmet safety standards:

EN 1078:
This is a European standard that specifies requirements and test methods for bicycle helmets. Key points of this standard include:

Construction: Helmets must protect the head and have a secure retention system to keep the helmet in place in case of an accident.
Shock absorption: Helmets must absorb and dissipate impacts effectively to minimize injuries.
Field of vision: Helmets must not obstruct the wearer’s field of vision.
Durability: Helmets must withstand wear and tear over time.
Labeling: Helmets must have clear and visible labeling indicating the helmet’s intended use, size, and other relevant information.

CPSC standards:
This is a US standard set by the Consumer Product Safety Commission. Key points of this standard include:

Impact protection: Helmets must protect against impacts from a minimum height of 2 meters, and absorb a significant portion of the impact energy.
Durability: Helmets must withstand repeated impacts and not break or lose effectiveness over time.
Labeling: Helmets must have clear labeling indicating their compliance with CPSC standards.

Both EN 1078 and CPSC standards are designed to ensure that bicycle helmets provide adequate protection for riders, and that riders can easily identify helmets that meet these standards.

What is the procedure to procure CPSC certification in the US?

To procure CPSC certification in the US, here’s a general outline of the process:

Determine Applicable Standards: Identify the specific safety standards that apply to your product. These are usually based on the type of product and its intended use.
Engage a CPSC-Accepted Lab: You must have your product tested by a CPSC-accepted laboratory. These labs have been approved by the CPSC to conduct testing for specific standards.
Perform Testing: The lab will test your product according to the applicable standards. The lab will provide you with a test report detailing the results.
Certify Compliance: If your product passes the testing, you must issue a Children’s Product Certificate (CPC) or General Certificate of Conformity (GCC), depending on your product. This certificate states that your product complies with all applicable safety standards.
Maintain Records: You must maintain records of your test reports and certificates for at least five years. These can be requested by the CPSC at any time.
Provide Certificates to Distributors/Retailers: You must provide your certificates to your distributors and retailers.

Remember, this is a general overview, and the specific process can vary depending on your product and circumstances. It’s always a good idea to consult with experts and/or the CPSC directly to ensure compliance.

For bicycle helmets what is the CPSC certification number and what test labs are recommended to carry out the tests at?

For bicycle helmets, the applicable standard for CPSC certification is the 16 CFR Part 1203: Safety Standard for Bicycle Helmets.

As for the certification number, it’s not a single number that all certified helmets share. Rather, each manufacturer or importer will issue a unique Children’s Product Certificate (CPC) or General Certificate of Conformity (GCC) for each product that complies with the standard. These certificates are what serve as proof of compliance.

As for recommended test labs, the CPSC maintains a list of accepted labs on their website. Here are a few labs that are accepted for testing bicycle helmets:

ACT Lab: ACT Lab performs consumer product safety and compliance testing for a wide variety of products, including bicycle helmets.
Intertek: Intertek is a leading quality assurance provider, offering testing, inspection, and certification services for a wide range of industries, including bicycle helmets.
SGS: SGS is a multinational company that provides testing, inspection, and certification services. They offer CPSC testing for a variety of products, including bicycle helmets.

UL (Underwriters Laboratories): UL is also an accepted test lab for CPSC testing, and they do perform testing and certification for bicycle helmets. UL has a wide range of testing facilities in the US and around the world, and they offer a variety of services for manufacturers, including safety testing, certification, and performance verification.

If you’re considering using UL for your bicycle helmet testing, you can contact them directly to get more information about their testing procedures, facilities, and pricing. Keep in mind that the CPSC maintains a list of accepted labs on their website, so you can always check there to make sure that any lab you’re considering is accepted for bicycle helmet testing.

Can you summarize CPSC 16 CFR Part 1203 https://www.ecfr.gov/current/title-16/chapter-II/subchapter-B/part-1203

The Code of Federal Regulations (CFR) Title 16, Part 1203 establishes safety standards for bicycle helmets. Here’s a summary:

• Purpose: To reduce the risk of head injury to bicyclists by establishing safety requirements for bicycle helmets.
• Scope: Applies to all bicycle helmets manufactured or imported for sale in the United States.
• Requirements: Helmets must meet certain performance criteria related to impact protection, retention system strength, and other factors. They must also have permanent labeling with safety information.
• Testing and certification: Manufacturers and importers must have their helmets tested and certified by a third-party laboratory to demonstrate compliance with the standard.
• Recordkeeping: Manufacturers and importers must maintain records demonstrating compliance with the standard for a specified period of time.
• Enforcement: The Consumer Product Safety Commission (CPSC) is responsible for enforcing the standard, and can issue civil penalties, injunctions, or other remedies for violations.

Overall, the purpose of 16 CFR Part 1203 is to ensure that bicycle helmets sold in the United States provide adequate protection against head injuries, and to give consumers confidence that the helmets they purchase meet certain minimum safety requirements.

Virgina Tech has a Helmet Lab that tests helmets and issues a 5-star safety rating. Can you tell me more about this lab?

Sure, here’s some information about the Virginia Tech Helmet Lab:

The Virginia Tech Helmet Lab is a research lab within Virginia Tech’s Department of Biomedical Engineering and Mechanics. The lab is dedicated to studying helmet safety and concussion prevention, and they test helmets for a variety of sports, including cycling, equestrian, football, and more.
The lab is run by Stefan Duma, a professor of biomedical engineering and mechanics, and his team of researchers.
One of the lab’s key initiatives is the Virginia Tech Helmet Ratings, which rates helmets based on their ability to reduce the risk of concussions. The ratings are based on the lab’s testing of helmets using specialized equipment that simulates real-world impacts.
The Virginia Tech Helmet Lab’s research has had a significant impact on helmet safety, with their ratings being widely used by consumers, coaches, and athletes to make informed decisions about helmet purchases and use.

Overall, the Virginia Tech Helmet Lab is a leader in the field of helmet safety research, and their work is helping to make sports safer for athletes of all ages and abilities.

Can I use them to get CPSC certification for the bicycle helmet that we at Numorpho Cybernetic Systems are creating?

While the Virginia Tech Helmet Lab’s research and ratings can provide valuable insights into helmet safety, they do not provide CPSC certification for bicycle helmets.

CPSC certification must be obtained through testing performed by a CPSC-accepted laboratory, as we discussed earlier. However, the Virginia Tech Helmet Lab’s ratings can certainly be used to inform the design of your helmet and help you ensure that it provides the best possible protection against concussions and other injuries.

In fact, many helmet manufacturers use the Virginia Tech Helmet Ratings as a guide when designing new helmets, striving to achieve the highest possible rating for their products.

In summary, while the Virginia Tech Helmet Lab cannot provide CPSC certification, their research and ratings can be a valuable resource for any manufacturer looking to create the safest possible helmets.

Our second helmet is a hard hat. It is 3D printed and foldable and has locks to prevent accidental opening and closing when in use. It has retainers with a ratchet mechanism to enable head fit, a 6-point suspension system to protect againt top impacts, chin strap (optional) to enable retention on the head and front padding cushion where the helmet contacts the forehead. Do hard hats like this need any certifications?

Yes, hard hats like the one you described would need to be certified to meet safety standards set by the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI).

Specifically, hard hats in the US need to comply with ANSI/ISEA Z89.1-2014, which sets out the requirements for protective headwear used in the construction, mining, and industrial sectors.

Some of the key requirements of this standard include:

Impact resistance: The hard hat must be able to withstand impacts from falling objects and debris.
Penetration resistance: The hard hat must be able to resist penetration from sharp objects.
Retention system: The hard hat must have a secure retention system to keep it on the wearer’s head.
Electrical insulation: The hard hat must provide some level of protection against electrical hazards.
Labeling: The hard hat must be clearly labeled to indicate that it meets the ANSI/ISEA Z89.1-2014 standard.

So, if you’re planning to sell your hard hat in the US, you will need to make sure it meets these requirements and is certified as such.

Can you describe the 4-point vs 6-point suspension system of hard hats and how they protect the user from impact?

Sure thing! The difference between 4-point and 6-point suspension systems in hard hats lies in the number of clips that attach the suspension cradle to the shell of the hard hat.

• A 4-point suspension system has 4 clips, while a 6-point suspension system has 6 clips.
• The additional 2 clips in a 6-point suspension system provide better protection against blows to the side of the head, as well as blows that come from an off-center axis.
• Essentially, the suspension system inside a hard hat helps to disperse the force of an impact. The more suspension points a hard hat has, the better it can disperse that force.

So, while a 4-point suspension system can provide basic protection, a 6-point suspension system offers more comprehensive protection, particularly against lateral impacts and off-center blows.

Do the clips need to be evenly distributed?

Technically, the clips in a suspension system don’t have to be evenly distributed to provide protection. However, most hard hats with suspension systems are designed so that the clips are evenly spaced around the circumference of the hard hat.

There are a couple of reasons for this:

• Evenly spaced clips can help ensure that the suspension system provides balanced protection against impacts from any direction.
• Evenly spaced clips can help make the hard hat more comfortable to wear, by distributing the weight of the hard hat evenly around the head.

That said, there are some specialized hard hats that may have unevenly distributed clips for specific applications or to accommodate other features, like face shields or earmuffs.

But for most general-purpose hard hats, evenly distributed clips are the norm, and help to ensure that the suspension system provides balanced and effective protection against impacts.

There is usually a circular patch at the top at the intersection of the ribbons of the suspension. What is the purpose of this? In some suspension systems, this circular patch is a thicker disk.

The circular patch at the top of the suspension system in a hard hat is called the crown strap or suspension cradle, and it serves a few different purposes:

• Impact absorption: The crown strap helps to absorb the impact of a blow to the top of the head by spreading the force of the impact across a larger area.
• Ventilation: The holes or slots in the crown strap can help to improve ventilation and airflow inside the hard hat, which can make it more comfortable to wear in hot or humid environments.
• Adjustment: Some crown straps are adjustable, allowing the wearer to customize the fit of the hard hat for better comfort and stability.

The thickness of the crown strap can vary depending on the design of the hard hat. A thicker crown strap may provide additional impact absorption, but it may also add weight and bulk to the hard hat. Ultimately, the design of the crown strap is just one factor in the overall safety and performance of a hard hat.

The retainer system is the ring that runs around the hard hat to enable better fit with typically a ratchet locking mechanism in the behind. Can you describe this in detail. Sometimes the rear portion of the retainer has a pivot to make it fit better just above the neck. Is there a reason for this?

Certainly, let’s dive in:

The retainer system, also known as the headband, is a key component of a hard hat that helps to ensure a secure and comfortable fit. Here’s how it typically works:

• The headband is made up of a flexible band of material, usually plastic or nylon, that wraps around the circumference of the hard hat just above the brim.
• At the back of the hard hat, there’s usually a ratchet adjustment mechanism that allows the wearer to tighten or loosen the headband to achieve a comfortable and secure fit.
• Some headbands also have a pivot point near the back, which allows the headband to flex and conform to the shape of the wearer’s head, particularly around the base of the skull. The reason for this pivot point is that heads come in all different shapes and sizes, and a pivoting headband can help to ensure a more customized and comfortable fit, especially for workers who need to wear a hard hat for long periods of time.

The front of the headband has a soft cushiony material that is replaceable. Can you describe this?

Absolutely! The soft, cushiony material on the front of the headband is called a sweatband or brow pad, and it serves a few important functions:

• Comfort: The sweatband provides a soft, padded surface that rests against the wearer’s forehead, which can help to reduce pressure points and make the hard hat more comfortable to wear.
• Sweat absorption: As the name suggests, the sweatband is also designed to absorb sweat and keep it from dripping down into the wearer’s eyes or onto the face. This can be especially important in hot or humid environments, or for workers who are engaging in strenuous physical activity.
• Hygiene: Many sweatbands are removable and replaceable, which makes it easy to clean or replace them as needed. This can help to prevent the buildup of dirt, oil, and bacteria, and keep the hard hat feeling fresh and hygienic.

In summary, the sweatband on the front of a hard hat’s headband is an important feature that helps to improve comfort, hygiene, and overall usability for workers who need to wear hard hats for extended periods of time.

I have seen some of the sweatband/brow pad made of leather? What purpose does this serve?

Leather sweatbands are typically used in hard hats for a few different reasons:

• Durability: Leather is a tough and long-lasting material that can withstand repeated use and exposure to harsh conditions, making it a good choice for hard hats that need to be worn frequently or in demanding environments.
• Comfort: Leather can be softer and more pliable than synthetic materials, which can help to reduce pressure points and improve overall comfort for the wearer.
• Moisture absorption: While leather may not be as absorbent as some synthetic materials, it can still help to wick away sweat and prevent it from dripping down into the eyes or onto the face.
• Style: Some workers simply prefer the look and feel of leather and see it as a more premium or traditional material for hard hat accessories.

Overall, leather sweatbands can offer a combination of durability, comfort, moisture absorption, and style, making them a popular choice for some workers who need to wear hard hats on a regular basis.

Now let’s do chin straps. Are they needed for hard hats?

Chin straps are not always required for hard hats, but they can provide some additional benefits, including:

• Improved retention: A chin strap can help to keep the hard hat securely in place, even if the wearer is moving quickly, bending over, or working in windy conditions.
• Hands-free use: A chin strap allows the wearer to keep the hard hat on their head without having to use their hands to hold it in place, which can be useful when working with tools or machinery.
• Compliance: Some workplaces or industries may require the use of chin straps as part of their safety protocols, even if they are not mandated by OSHA or other regulatory agencies.

That said, chin straps are not always practical or comfortable for every worker or every application. Some workers may find them restrictive or annoying to wear, and they can also pose a safety hazard if they get caught on machinery or other objects.
Ultimately, the decision to use a chin strap with a hard hat will depend on the specific needs and preferences of the worker, as well as any safety regulations or requirements that apply to their workplace or industry.

Chin straps typically have a “Y” around the ears. Is this a better design rather than a single strap?

The “Y” shaped chin strap design, also known as a three-point chin strap, is generally considered to be a more effective and comfortable design than a single strap for a few reasons:

• Stability: The three-point design helps to distribute the force of the chin strap more evenly across the head, which can provide better stability and prevent the hard hat from tilting or shifting.
• Comfort: The “Y” shape can help to reduce pressure points around the ears and jawline, which can make the chin strap more comfortable to wear for extended periods of time.
• Safety: In the event of an impact, a three-point chin strap can help to prevent the hard hat from being knocked off the head, which can provide additional protection to the wearer.

Overall, while a single-strap chin strap can still provide some benefits, a three-point chin strap is generally seen as a superior design that can offer better stability, comfort, and safety for workers who need to wear hard hats with chin straps.

I have seen the second strap of the Y in the three-point chin strap point towards the rear apex of the helmet? Is there a “safety” reason for this?

Yes, there is indeed a safety reason behind this design feature.

• When the second strap of the “Y” in a three-point chin strap points towards the rear apex of the hard hat, it helps to ensure that the chin strap remains securely in place in the event of a backward or rearward impact.
• Without this rearward-pointing strap, the chin strap could potentially slide forward off the head in a rearward impact, which could compromise the protection provided by the hard hat.
• By securing the chin strap to the rear apex of the hard hat, the three-point design helps to ensure that the hard hat stays firmly in place, even in the event of a backward impact.

This is especially important for workers who may be at risk of falling objects or other hazards from above, as a properly secured hard hat can provide critical protection against head injuries in these situations.

What are the pros and cons of chinstraps that do not have the Y three point?

The pros and cons of chin straps that do not have the three-point “Y” design largely depend on the specific type of chin strap being considered. Here are some general points to consider:

Pros:

Simplicity: A simpler chin strap design may be easier to adjust and use, particularly for younger or less experienced cyclists.
Cost: A simpler chin strap design may be less expensive to manufacture, which could result in lower costs for consumers.
Comfort: Some cyclists may find simpler chin strap designs more comfortable, particularly if they experience irritation or discomfort from the additional straps in a three-point design.

Cons:

Stability: A simpler chin strap design may not provide the same level of stability and retention as a three-point design, which could increase the risk of the helmet shifting or coming off in an accident.
Safety: Depending on the specific design, a simpler chin strap may not provide as much protection against facial injuries as a three-point design.
Certification: Depending on the specific design and safety standards being applied, a simpler chin strap may not meet certain safety requirements, which could limit its use or sale in certain jurisdictions.

Ultimately, the choice of chin strap design will depend on a variety of factors, including personal preference, intended use, and applicable safety standards.

What is the purpose of the jaw cup in a chin strap. Is this needed for bicycle helmets?

The jaw cup in a chin strap, also known as a chin guard or chin pad, serves a few different purposes:

• Comfort: The jaw cup provides a soft, padded surface for the chin to rest against, which can help to reduce chafing, irritation, and discomfort during extended wear.
• Stability: By cradling the chin, the jaw cup can help to prevent the hard hat or helmet from sliding forward or backward on the head, which can improve stability and retention.
• Safety: In some cases, the jaw cup can provide additional impact protection for the chin and jaw area, particularly in high-impact sports like football or hockey.

As for bicycle helmets, the need for a jaw cup depends on the specific design of the helmet and the intended use. Many bicycle helmets do not have jaw cups, as they are primarily designed to protect the top and sides of the head from impact.

However, some full-face bicycle helmets, particularly those used for extreme sports like downhill mountain biking or BMX racing, may have jaw cups or chin guards to provide additional protection against facial injuries.

Does UL provide testing to meet ANSI/ISEA Z89.1-2014 certification for hard hats?

Yes, UL does indeed offer testing services to certify hard hats for compliance with the ANSI/ISEA Z89.1-2014 standard. UL is a leading safety science company that provides testing, inspection, and certification services for a wide range of products and industries, including personal protective equipment (PPE) like hard hats.

To get your hard hats certified by UL, you would need to submit your product to UL’s testing laboratory, where they would conduct a series of tests to ensure that your hard hats meet the requirements of the ANSI/ISEA Z89.1-2014 standard.

Once your hard hats have passed the tests, UL will issue a certification report and mark that you can use to demonstrate compliance with the standard. This certification mark is widely recognized in the industry and can help give your customers confidence that your hard hats meet the necessary safety requirements.

Great. What if the hard hats were sold to be worn at baseball games and as a swag in modern art museum stores? Do I need extensive certifications for this if the intent is for non-industrial purposes?

That’s a great question! The answer really depends on how you market and advertise your hard hats.

If you’re marketing your hard hats as a novelty item, souvenir, or piece of art, rather than as safety equipment, then you may not be required to obtain industrial safety certifications.

However, it’s important to be clear in your marketing materials and packaging that your hard hats are not intended for use in industrial or construction settings, and that they do not meet industrial safety standards.

Additionally, you may still want to ensure that your hard hats meet some basic safety standards, even if they’re not intended for industrial use. For example, you may want to make sure that they’re made from non-toxic materials and that they don’t pose any choking hazards.

Overall, while you may not need extensive industrial safety certifications for hard hats sold as novelty items, it’s still important to consider the safety of your customers and ensure that your products are safe and appropriate for their intended use.

Can we say that “they have not been tested to meet industrial safety standards” rather than “they do not meet industrial safety standards”?

Yes, that’s a much better way to phrase it! Saying that your hard hats “have not been tested to meet industrial safety standards” is more accurate and less likely to be misinterpreted.

It’s important to be precise in your language when describing the safety features of your products, and this phrasing makes it clear that your hard hats simply haven’t been tested for industrial safety, rather than implying that they’re inherently unsafe or defective.

Additionally, you may want to include some language on your packaging or marketing materials that clearly states the intended use of your hard hats, such as “For novelty use only. Not intended for use in industrial or construction settings.”

By being transparent about the safety features and intended use of your hard hats, you can help ensure that your customers are using them safely and appropriately, while also protecting yourself from potential liability or legal issues.

nitin.uchil@numorpho.com