We have created innovative customizable hard hats and smart helmets for manufacturing, construction, military, first responder/firefighter, urban wear, recreation and wellbeing constituencies using a unique design pattern, parametric modeling, additive manufacturing and sensor embeddings.

This post accounts for our progression on our path to commercialization for our smart helmets.

Most of the milestones have been cataloged in LinkedIn as they happened.

TABLE OF CONTENTS

Roadmap Progression

• 20240519 – Showcase at the Distinguished Gentlemen’s Ride @ Cobra Lounge
• 20240521 – Product Showcase for Montessori Middle School
• 20240523 – Meeting with SBA.org
• 20240524 – Impromptu show and tell at mHUB Happy Hour
• 20240527 – Memorial Day Post
• 20240529 – DFMEA basis for testing our helmets
• 20240605 – Packaging Perspective
• 20240610 – Ready for Assembly!
• 20240610 – Helmet Color Standardization
• 20200611 – Padding Insets User Input
• 20240613 – Bento Box: Slicing the paddings
• 20240618 – Wurth Demo Day @ Chicago
• 20240620 – Hardware Meetup sponsored by Particle.io and Field Theory
• 20240622 – Additive Manufacturing and Customization
• 20240627 – Gyroid Infill Pattern
• 20240629 – Material Sciences and AM
• 20240630 – Welcome to the Ball Game!
• 20240704 – Process Focused Solutions
• 20240706 – Carbon Fiber Infused Filaments
• 20240709 – The “Maki”ng of the Sushi Boat!
• 20240731 – Material Matters
• 20240805 – Detachable Encasements
• 20240806 – Test Coupons for Additive Manufacturing
• 20240808 – Multi-modal basis for Smart Monitoring
• 20240812 – RGB and you can have any color you want
• 20240816 – Armadillo Design Concept
• 20240819 – Hardhats to Safety Helmets – Padding our Industrial Helmets
• 20240820 – For Women in Construction
• 20240821 – Brownfield Retrofit for Smart Monitoring
• 20240825 – Simulating Lattice Structure Breakage
• 20240901 – Reducing Scaffolding Waste in 3D Printing
• 20240904 – Twinning One-shot Printing for the Hard Hat
• 20240904 – Graceful Attenuation Testing
• 20240928 – One Shot Printing of Urban Hard Hats
• 20241218 – Smart Helmets in Peru – Thank you Arduino!
• 20250127 – Migration to Onshape and using PETG HF

1. ROADMAP PROGRESSION

20240519 – Showcase at the Distinguished Gentlemen’s Ride @ Cobra Lounge

Rumble time for Numorpho Cybernetic Systems (NUMO) smart helmets.

We showcased our helmet at the The Distinguished Gentleman’s Ride event that started across from mHUB today morning and it was an immediate hit. The wow factor of the foldability and the electronic componentry add were key factors.

Thank you, @Peter Papai for the invite. We got several suggestions on the padding, chin strap and storability of the helmet that we plan to incorporate for motorcycle riders so this will be another domain to add for our path to commercialization.

20240521 – Product Showcase for Montessori Middle School

From distinguished to impressionable, our journey of commercialization showcased the different helmets to Montessori Middle School students visiting mHUB.

20240523 – Meeting with SBA.org

20240524 – Impromptu show and tell at mHUB Happy Hour

So you better strap on the helmet, because Kansas is going bye-bye.

20240527 – Memorial Day Post

Red vs Blue. Let the games begin. Numorpho Cybernetic Systems (NUMO) Hard hats and Urban helmets are ready for prime time.

Today on Memorial Day, we showcase our smart helmets in red and blue to pay respect to the uncountable lives of our front-line soldiers that have made our country free and safe.

We have utilized two different materials in printing the helmets. The Blue is ABS and the Red is PETG. Both ABS and PETG are popular materials for 3D printing production parts, and each has its own strengths and weaknesses that we have detailed in our whitepaper (to be published subsequently in this thread).

Here is a summary:
– ABS is a bit stronger and more impact resistant.
– PETG is more flexible and shatter-resistant than ABS, and resistant to UV light and water
– PETG will also help better attenuate the shock of a collision.
– PETG is the more sustainable and environmentally correct solution.
– PETG, however is a finicky material to 3D print and susceptible to humidity that can create warpages if the printer is not enclosed or the filament is left open to the elements.
– PETG is also 30% heavier than ABS.

When doing impact testing for helmets, it not just how strong the material is, but also how it muffles the shock of the blow and prevents or minimizes injury to the head. It also depends on the foam/flexible padding, the fit of the retainers and suspensions, and the chin strap that would prevent the detachment of the helmet on impact that play key factors in safety. We will also be conducting digital simulations of the impact test to see if we can modify the infill lattice structure to have regions of variable density to match up with the needs to resist impact while optimizing the weight of the helmet.

Based on these considerations, we will be moving to the next phase – small batch manufacturing and test validation for certifications based on the different safety standards so that we are progressing on our path to commercialization.

#3dprinting #am #ppe #memorialday #materialsengineering #petg #abs #helmet

PETG vs ABS vs ASA

ASA vs ABS

20240529 – DFMEA basis for testing our helmets

Thank you, Balakrishnen Varadarajan. We at Numorpho Cybernetic Systems (NUMO) are building our test cases for our helmet variants not only to comply with the different regulations for safety but also to ensure that our uniquely developed product (using additive manufacturing) protects the user from harm.

DFMEA (Design Failure Mode and Effects Analysis) is a systematic approach used in product design and manufacturing to identify and assess potential failure modes in a product or process, and to determine their effects on the overall system. The purpose of DFMEA is to help designers and engineers anticipate potential problems and design solutions that mitigate the risks associated with those problems. The process involves identifying all of the possible failure modes for a particular product or process, analyzing the effects of those failures, and then prioritizing them based on their severity, likelihood of occurrence, and ability to be detected.

Our first foray with the AI-FMEA tool from Twinmo.ai has been amazing and our intention is to utilize it as part of our product and process lifecycle management to ensure that our solutions meet the exacting standards of the industry and meet and exceed customer expectations.

Thank you also to the EIRs (Experts in Residence) at mHUB : Bob Daniel-Wayman, Karthik Chandramouli and Paul Cushman whom we meet up every Wednesday to ideate and iterate on our solutions. This support has been invaluable for our progression.

https://www.linkedin.com/posts/balakrishnen-varadarajan-04244012_hey-product-folks-i-wanted-to-run-something-activity-7201383244510973952-w4l2?utm_source=share&utm_medium=member_desktop

Here is the complete DFMEA for all the Helmet types generated by our partner company, TWINMO AI https://numorpho.org/wp-content/uploads/2024/06/TWINMO_Helmet_FMEA_V04.xlsx

20240605 – Packaging Perspective

We are theming out a unique way to package and stack our smart helmets. Thank you, Wynalda Packaging for this initial concept.

We plan to add a compelling graphic on the prismatic sides of the package to enable them to be immediately noticeable on store fronts for our bicycle, urban and hard hat variants.

Our other PPE Helmets for Industrial workers, Construction, Military and First responders will be sold via our partner distribution channel we are building, and we will be syndicating our product catalog with the details to them.

20240610 – Ready for Assembly!

Our smart helmets 3D printed using PETG are undergoing small batch manufacturing in readying them for compliance testing. Depicted here are the Industrial, Construction, Hard Hat and Bicycle variants and the tools (screws, nuts and lock pins – thank you McMaster-Carr) needed for assembly.

The white paddings are TPU printed with no walls and provide for the soft support between the shell and the head.

Thank you, Anthony Anton, Tyler Grudowski and Yuri Gallegos (the 3D Amigos) for setting up the 3D print farm for enabling such small batch production runs. They are part of the mHUB ecosystem.

Following assembly, we will be embedding the industrial and construction variants with Arduino’s Nicla Sense ME sensors for motion and environmental detection that is part of our CONNECT-DETECT-PROTECT protocol for smart monitoring at Numorpho Cybernetic Systems (NUMO).

As part of our mobility solutions, we will be integrating sensor data with other IoT device data to provide for a holistic understanding for process engineering for analytics, dashboards and predictive operations so that proactive measures can be implemented for safety, optimization and harmonization of industry and commercial operations. This will enable organizations to leverage the power of their data in new ways, providing valuable insights for decision-making and driving innovation across a wide range of industries.

Marketing Spheel:

Our mobility solutions are designed to provide a comprehensive view of all aspects of the organization, from production processes to supply chain management, giving decision-makers the information they need to optimize operations, reduce costs, and improve overall efficiency.

With advanced analytics, customizable dashboards, and predictive modeling capabilities, our mobility solutions can help organizations stay ahead of the curve, identifying potential issues before they arise and taking proactive measures to mitigate risks and improve overall performance.

Whether you are looking to optimize your manufacturing processes, improve supply chain visibility, or enhance customer engagement, our mobility solutions provide the tools you need to succeed in today’s fast-paced, data-driven business environment.

#ppe #helmet #3Dprinting #additive

https://filament2print.com/gb/blog/52_petg-abs-asa.html

20240610 – Helmet Color Standardization

We intend to adhere to standard colors for the industry.

• White: Often reserved for administrative roles such as managers, engineers, foremen and all kind of supervisors.
• Blue: The color normally attributed to technical operators, most notably electricians, carpenters and all kinds of specialized workers.
• Green: Typically, workers wearing a green safety helmet are safety officers.
• Red: Much as it happens outside the construction site, this color is reserved for firefighters.
• Yellow: This tends to be the predominant helmet color in any given construction site, as it’s assigned to general laborers.
• Brown: Reserved for workers involved in high heat applications, including but not limited to welders.
• Grey: Site visitors will be given these hats to tell them apart from the site workers.

And for swag, you can have any color or as many colors as you want!

20200611 – Padding Insets User Input

We wanted breathable faces which were in contact with the head to enable ventilation. So, we devised a unique, by part object slicing for each of the padding component where the apexes (front and rear) had walls for the sides, and the slat paddings had walls top and bottom.

Sushi-sashimi bento box platter, anyone.

20240618 – Wurth Demo Day @ Chicago – EVERYTHING CONNECTED – Numorpho’s Book of Business

As discussed with Grant Michel @ Wurth Additive Group, our goal would be to have a defined set up with key manufacturers like Uptive Manufacturing, The 3D Amigos and maybe MakeLab to send the recipe of our helmets securely to their print farms/facilities and manage the fluent flow of the making between contract houses – materials and sensors procurement, printing, vapor smoothening, component adds and accessories inclusion for example using Wurth Additive’s Digital Inventory Services that would be API driven by the Mantra M5 platform.

Once certified, Wurth’s Northern Safety Division could be keen on having this in their PPE catalog – like one of their traveling salespersons mentioned “Its convenient”!

20240620 – Hardware Meetup sponsored by Particle.io and Field Theory

Demoed our helmets at the meetup.

Particle.io makes IoT PCBs

Field Theory makes antennas and connectivity stacks.

20240622 – Additive Manufacturing and Customization

Body-translucent, Body-in-white, Body-in-color. You can have Numorpho Cybernetic Systems (NUMO) hard hats in any color you want, no exceptions!

“You can have any color, as long as it’s black” is a quote attributed to Henry Ford, which appears in his 1922 autobiography, My Life and Work. The quote is related to the color of the Model T, which was only available in black from 1914–1925. This was to streamline the assembly line process to have a cadence in manufacturing.

Fast forward to today, where additive manufacturing is enabling customization on an individual part basis in terms of color and other characteristics both to enable structural optimization as well as mass customization. We are keen on building our own “proto factory” to showcase the art of these possibilities coupled with the science and math of engineering to enable intelligent process engineering.

In the auto industry, BIW or body-in-white is the first representation of the vehicles test mule without any of the additional components to visualize the overall geometry and physical characteristics.

In the attached pictures, you see our forays into smart and advanced manufacturing techniques. We have deliberately printed our first helmet in translucent filament to enable the viewing of the inner lattice structure so that we can see what happens during impact testing.

#additivemanufacturing

20240627 – Gyroid Infill Pattern

https://wiki.bambulab.com/en/software/bambu-studio/fill-patterns#infill-types-and-their-properties-of-sparse details the different infill patterns available in the Bambu Studio slicer.

Shown below is the Gyroid fill for the Hard hat Slats 1 and 2 that we will using to reverse simulate impact testing by creating a mesh of the sliced geometry using LS-Dyna.

• Innovative Helmet Design – A Discourse with Claude.ai

20240629 – Material Sciences and AM

It’s all about stress and strain, be it in engineering or life.

Young’s Modulus, also known as the elastic modulus, is a measure of a material’s stiffness or resistance to elastic deformation. It is named after Thomas Young, the British scientist who first described it in the early 19th century.

Young’s Modulus is typically represented by the letter “E” and is defined as the ratio of stress (force per unit area) to strain (deformation per unit length) in a material that is being stretched or compressed. In other words, it tells you how much force is required to stretch or compress a material by a certain amount.

The value of Young’s Modulus depends on the material being tested and can range from very low (for soft, elastic materials like rubber) to very high (for stiff, rigid materials like steel). It is an important parameter in engineering and materials science, as it can be used to predict and design the behavior of structures and components under different loads and conditions.

In the following article Carolyn Carta, MS, PhD (Dr. CC) discusses how Young’s Modulus pertains to medical devices, eyeglass lenses, protecting art, and our domain at Numorpho Cybernetic Systems (NUMO), additive manufacturing.

https://lnkd.in/gUMEjKTW

As we progress from using PLA (for concept and prototype) to more robust and production ready materials like ABS, PETG and ASA, do simulations using appropriate MATerial cards with stress-strain properties and test for impact we have to be mindful of using the correct materials and their properties for graded attenuation during a crash.

We have detailed this and other engineering aspects like padding, gyroid fill for the lattice structure of the shell of the helmet (James Shaw), the effect of vapor smoothing (smoothening) and utilizing continuous fiber reinforcement (Markforged) that we will be incorporating in the innovative design of our helmets, its testing and production runs.

Our association with MxD, mHUB , CArtLab Solutions, and Fastway Engineering, and our partnerships with Würth Additive Group, UPTIVE Manufacturing and Arduino are helping us fast track our progression in hashtag#additivemanufacturing and hard tech to enable us build products that are smart, connected and useful to our consumers.

20240630 – Welcome to the Ball Game

Be protected against fly balls wearing a Numorpho Cybernetic Systems (NUMO) helmet.

Herewith, we present with no bias or discrimination our helmets printed in the colors of the White Sox and the Cubs printed in PETG and ASA respectively. Go Cubs, go White Sox. May the best filament material win.

We also have our helmets printed using clear translucent filaments with the traditional default grid lattice structure and the more robust gyroid infill pattern. Our crash testing of these helmets will showcase the resiliency of these fill patterns during an impact. The gyroid is an interesting choice for helmet applications because of:

1. Isotropic properties: The gyroid structure has uniform properties in all directions, which is ideal for a helmet that needs to absorb impacts from various angles.
2. Continuous structure: Unlike some other patterns, the gyroid is a continuous structure without sharp corners or abrupt transitions. This can help in distributing forces more evenly throughout the helmet.
3. Self-supporting: The gyroid pattern doesn’t require additional support structures during printing, which can simplify the manufacturing process.
4. Excellent energy absorption: The complex, curved structure of the gyroid can provide superior energy absorption compared to simpler patterns.
5. Fluid permeability: While not directly related to impact protection, the gyroid’s permeability could potentially be leveraged for ventilation or integration of other materials.
6. Scalability: The gyroid pattern can be easily scaled to adjust density and mechanical properties.

In another news, in another ball game called cricket, India wins the world cup yesterday. Thank you, Deepak Kulkarni for distracting me with the results of this event as we were admiring the architecture of Chicago and discussing Limit State Design that is the civil engineering thesis for reinforced concrete structures. Happenstance, team India’s colors correspond to the Cubs. Go figure!

What is Limit State Design?

Limit state design (LSD), also known as load and resistance factor design (LRFD), is a design method used in structural engineering to ensure that a structure can safely withstand all possible loads and conditions it may encounter throughout its lifetime.

The basic idea behind LSD is to identify the various “limit states” that a structure may experience, such as ultimate limit states (e.g., collapse or failure) or serviceability limit states (e.g., excessive deflection or vibration). For each limit state, the designer must calculate the expected loads (e.g., dead loads, live loads, wind loads) and the corresponding resistances (e.g., strength of materials, stiffness of components) of the structure. The loads and resistances are then multiplied by safety factors to account for uncertainties and variations in the design assumptions. The structure is considered safe if the design resistance is greater than or equal to the design load for all relevant limit states.

LSD has become a widely used design method in modern engineering practice, as it provides a more rational and consistent approach to ensuring the safety and performance of structures compared to traditional allowable stress design (ASD) methods.

Chicago Cubs Chicago White Sox

20240704 – Process Focused Solutions

This article continues the thesis of CArtLab Solutions wherein Carolyn Carta, MS, PhD talks about process-focused solutions.

https://www.linkedin.com/feed/update/urn:li:activity:7214005072865767424/

Section 4 discusses Additive Manufacturing capabilities:

“4️⃣ 3D Printing:
Process Improvement: Multi-Material Printing and High-Speed Sintering – Advances in 3D printing technology now allow for the simultaneous use of multiple materials in a single print, enhancing the functionality and complexity of printed parts. High-speed sintering increases production speed without compromising quality.
Impact: These improvements expand the capabilities of 3D printing, enabling the production of complex, functional, and durable parts for a wide range of applications, from rapid prototyping to final product manufacturing.”

At Numorpho Cybernetic Systems (NUMO), our basis is to engineer processes using our Mantra M5 platform by enabling upstream (product development), midstream (manufacturing) and downstream (aftermarket) activities to be coordinated by connecting the dots between people, processes and technology.

As we pivot from our initial set of products (smart 3D printed helmets) to other products in the e-mobility space, we will be utilizing these advanced techniques to bear to conjoin the art of the possible with the science and math of engineering. Our partnerships with Würth Additive Group, UPTIVE Manufacturing and Fastway Engineering will help us conform our designs, and prototype and produce our solutions.

Interactions such as this brings focus to our intentions and helps fine tune our capabilities. Thank you, Dr. CC.

📣 Additive Manufacturing Community 📣: The FDA has recently updated their Recognized Standards List to include four newly recognized #standards on #AM under the #Materials category.

• ASTM F3456-22: Standard Guide for Powder Reuse Schema in Powder Bed Fusion Processes for Medical Applications for Additive Manufacturing Feedstock Materials
• ISO/ASTM 52926-1 First edition 2023-11: Additive manufacturing of metals—Qualification principles—Part 1: General qualification of operators
• ISO/ASTM 52926-2 First edition 2023-11: Additive manufacturing of metals—Qualification principles—Part 2: Qualification of operators for PBF-LB
• ISO/ASTM 52926-3 First edition 2023-11: Additive manufacturing of metals—Qualification principles—Part 3: Qualification of operators for PBF-EB

20240706 – Carbon Fiber Infused Filaments

What do you get when you merge carbon fiber infused filaments with gyroid lattice pattern infill? Amazingly strong helmets that’s what!

In this, our next iteration at Numorpho Cybernetic Systems (NUMO), we are 3D-printing the helmets with PETG-CF to make our smart helmets additionally strong. This innovative combination leverages the best of both worlds:

1. Carbon Fiber Reinforced PETG (PETG-CF):
   • Enhanced strength-to-weight ratio compared to standard PETG
   • Improved stiffness and dimensional stability
   • Better heat resistance, crucial for helmet applications
   • Reduced warping during printing, allowing for more precise geometries
2. Gyroid Lattice Infill:
   • Continuous, self-supporting structure that distributes forces efficiently
   • Excellent energy absorption properties, vital for impact protection
   • Isotropic mechanical properties, ensuring consistent performance in all directions
   • Customizable density for optimizing strength and weight

The synergy between PETG-CF and gyroid infill creates a helmet structure that is:

• Exceptionally strong yet lightweight
• Highly impact-resistant due to efficient energy distribution
• Thermally stable, maintaining integrity in various environmental conditions
• Customizable for different impact protection requirements

This advanced manufacturing approach allows NUMO to:

• Fine-tune helmet performance for specific use cases (e.g., industrial, sports, military)
• Potentially reduce overall helmet weight while maintaining or improving protection
• Create more complex internal structures that weren’t feasible with traditional manufacturing
• Rapidly iterate designs based on testing and user feedback

Furthermore, this combination opens up possibilities for:

• Integrating sensor and other fault detection mechanisms systems within the gyroid structure to detect cracks and failures.
• Optimizing ventilation channels through strategic design of the gyroid pattern (we are investigating this in the URBan version of the helmet).
• Creating gradient structures where density varies across the helmet for targeted protection. We are in the process of running CAE simulations using Ansys LS-DYNA to investigate regions of high and low stress to appropriately change the topographic density of the lattice structure.

By pushing the boundaries of materials science and additive manufacturing, we at NUMO are setting new standards in helmet design and performance. This innovative approach not only enhances safety but also paves the way for the next generation of smart, responsive protective gear. Go #PPE.

Like they say in the Matrix: Hang on to your helmet, Dorothy. ‘Cos Kansas is going bye-bye!

#additivemanufacturing

20240709 – THE “MAKI”NG OF THE SUSHI BOAT

20240731 – Material Matters

To enable smart monitoring with existing PPE and head gear, we are including a lanyard-based sensor enclosure showcased below to house the Arduino Nicla Sense ME and other componentry to monitor motion and environmental conditions.

For the helmets, we are using ASA, PETG and PETG-CF as the go to materials for 3D printing. Using ABS we noticed that the material is too brittle/does not have flex and broke when we were opening the latch of the enclosure, the blue tiny part next to the last image…..

20240805 – Detachable Encasements

Our Guardian #PPE foldable Helmets at Numorpho Cybernetic Systems (NUMO) come with a detachable smart casing to house sensors that can also be worn with a lanyard to CONNECT-DETECT-PROTECT.

CONNECT-DETECT-PROTECT is our smart monitoring protocol to gather sensor information from our mobile devices and coordinate it with other real time IoT data to analyze, alert and inform to warn, help operate, enable make decisions and protect personnel from harm. It will enable:

• situational awareness,
• environmental assessment,
• operational safety, and
• functional efficiency.

The goal is to have a multi-modal integrated smart monitoring system that would be configurable to the use case be it for law enforcement personnel, first responders, fire-fighters, industrial and construction workers, urban riders or even in well care institutions. We will be working with industry leaders to institute a data engineering fabric and utilize generative AI, simulations and inference engines for the theming of actionable intelligence.

For this version created for the police, we have the shell 3D printed and constructed in Carbon Fiber composite that is both strong and light weight. The encasements have Arduino PRO Nicla Sense ME sensors to detect motion and environmental conditions. Future versions will have Vision and Voice integrated.

Dovetailing with the mission of the Police Department to Serve and Protect, we at Numorpho strive to provide advanced technological solutions that enhance the safety, efficiency, and effectiveness of police officers in the line of duty. Our Guardian PPE foldable Helmets, equipped with smart sensing capabilities, demonstrate our commitment to delivering cutting-edge innovations that adapt to the unique challenges faced by law enforcement professionals.

By incorporating the CONNECT-DETECT-PROTECT protocol, we aim to create an ecosystem where real-time data from various sources can be seamlessly integrated and analyzed, empowering police officers to make informed decisions and respond proactively to potential threats or emergencies.

As we move forward, we will continue to collaborate with industry leaders to refine our data engineering fabric and leverage emerging technologies like generative AI, simulations, and inference engines. This multidisciplinary approach will enable us to provide actionable intelligence and drive the evolution of our smart monitoring solutions, ensuring that police officers remain protected and connected in the field.

At Numorpho, we are dedicated to serving those who serve our communities, and we look forward to further advancing our technologies to meet the dynamic needs of law enforcement agencies worldwide. Together, we can create a safer and more secure future.

20240806 – Test Coupons for Additive Manufacturing (aka Mini-Me)

In my conversation with Grant Michel from the Würth Additive Group on the nuances of 3D printing, here is a suggestion from him that makes tremendous sense as we navigate the waters of additive manufacturing:

“Alongside the part print, we should institute the creation of a test coupon that would represent the nuances of the printed part. This test coupon could then be independently tested without destroying the actual part.”

Since the test coupon is created in conjunction with the part, all of the environmental and print conditions are captured in it to give real equivalent analysis for the part. This would serve to validate the part similar to employing quality control in traditional manufacturing where 1 in a certain amount is picked for testing. Here, every part can be certified by simply validating the test coupon.

Key Benefits:

• Independent testing: The test coupon can be tested without destroying the actual part, allowing for non-destructive evaluation.
• Real equivalent analysis: The coupon provides an accurate representation of the part’s properties, enabling reliable validation.
• Quality control: Every part can be certified by validating the test coupon, similar to traditional manufacturing’s quality control methods.

Implementation:

• Create a test coupon alongside each part print
• Ensure the coupon captures the same environmental and print conditions as the part
• Test the coupon independently to validate the part’s quality and properties

By adopting this approach, manufacturers can ensure the quality and validity of their additively manufactured parts, streamlining the production process and building confidence in the final products.

I also had a conversation with James Shaw from Fastway Engineering on how such test coupons could be created digitally using simulations to correspond with the exact engineering conditions that are needed for the part. We will be working with Jim and team to create the exact Materials Card so that the simulation has a basis for analysis. This will be done using Deep Learning Surrogates to interpolate the values from physical testing.

As we progress on our journey with additive manufacturing utilizing our “Born, not Built” philosophy, it is essential and critical for us to validate our products so that the solution works in its operating conditions and performs as expected in its intended environment. By leveraging digital simulations and Deep Learning Surrogates, we can create a comprehensive understanding of our additively manufactured parts’ behavior under various conditions.

Employing recipes for additive manufacturing as suggested by @Wurth based on their Digital Inventory Services would require the exact prescribing of materials and conditions for creating parts. A “Mini-Me” test coupon that resides alongside will go a long way to provide for the trustworthiness of the part akin to DNA evidence in forensic studies.

Stay tuned for more details on this amazing adventure we are embarking on.

20240808 – Multi-modal basis for smart monitoring

In conversation with Robby Campoverde from Arduino.

Initial Basis – Motion and Environmental Monitoring – Nicla Sense ME

Version 2 – Vision Monitoring – Nicla Vision, Stroma Vison, Sony AITRIOS

Version 2.1 – Voice and Sound – Nicla Sound

Version 3 – Haptic – ?

Version 3.1 – Display – Azumo Tech

The sushi-sashimi bento box for paddings for the Industrial Helmet (CDP-G2) come with Broccoli spears, to include nubs for the rear ratchet retainers for the safety helmet.

20240820 – FOR WOMEN IN CONSTRUCTION

Congratulations, Smita Sahoo, on joining mHUB !

We at Numorpho Cybernetic Systems (NUMO) are thrilled to collaborate with āśaya I DESIGN on this groundbreaking initiative for women in construction, architecture, and design.

Our partnership is set to revolutionize Personal/Personnel Protective Equipment (PPE) and for women in these industries. By combining your expertise in architectural design with our cutting-edge additive manufacturing and smart technology, we’re creating PPE that’s not just protective, but also innovative, comfortable, and tailored specifically for women’s needs.

Our flagship PPE product, a smart, foldable helmet, exemplifies this approach:

1. Customized Fit: Using 3D printing, we can create helmets that perfectly fit the diverse head shapes and sizes of women in the field.
2. Lightweight Yet Strong: Our use of carbon fiber-reinforced PETG with a gyroid infill structure ensures optimal protection without unnecessary weight.
3. Smart Features: Optional Embedded sensors provide real-time safety monitoring and environmental awareness, crucial in dynamic construction environments.
4. Foldable Design: Addressing the practical needs of professionals on the go, our helmet’s unique folding mechanism enhances portability without compromising safety.
5. Climate Sensitivity: The advanced materials and design allow for better ventilation and comfort in various weather conditions.
6. Sustainability: Our additive manufacturing process minimizes waste, aligning with the growing focus on sustainability in construction and design.

By leveraging mHUB’s resources and network, we’re poised to rapidly prototype, test, and refine our designs. This collaboration represents a perfect synergy of architectural insight, cutting-edge technology, and a deep understanding of women’s needs in these industries.

We’re excited about the potential to not only enhance safety but also to empower women in construction, architecture, and real estate with equipment that’s designed specifically for them.

Looking forward to the amazing innovations we’ll create together!

20240821 – BROWNFIELD RETROFIT FOR SMART MONITORING

Smart Monitoring: Connect-Detect-Protect – EVERYTHING CONNECTED – Numorpho’s Book of Business

Smart monitoring is the judicious use of the different sensors to collect data using edge devices in a strategic and efficient manner. The sensors used for smart monitoring can vary depending on the application, but some common types include vision sensors, temperature sensors, humidity sensors, pressure sensors, proximity sensors, and motion sensors.

Digital and smart manufacturing is a need as we begin to rely more on local and onshore production capabilities. It is even more pertinent due to fact that the workforce is aging – the silver tsunami effect – and the need to automate is ever more pertinent. With the advent of new engineering like Additive Manufacturing we are able to build complicated parts that require a different skill set to design and make.

MxD has a unique sensor kit set that enables brownfielding of manufacturing plants – retrofitting equipment with sensors to make them smart for IoT and other Industry 4.0 protocols to better communicate. In conjunction with MxD, we will utilize their sensor kit to elevate the SMM facilities to retrofit smart devices to existing equipment providing “simple no-code solutions” for pertinent use cases that enabled process optimization and cost savings and “experience the benefits of digitization.”

This fits well with Numorpho’s CONNECT-DETECT-PROTECT theme. A comprehensive smart monitoring application is being devised by combining the data from static (in place sensors) with dynamic/roving sensors like those attached to our helmets and other ARVs. This approach would not only help safety on but also enable operational efficiency by instituting quality control methods and preventative maintenance procedures on the factory floor.

20240825 – Simulating Lattice Structure Breakage

https://www.linkedin.com/feed/update/urn:li:activity:7233443203922726912/

As we progress with the basis for lattice in-fills for our additively manufactured helmet shells, we will be looking at CAE technologies such as this to simulate the behavior of the 3D prints a priori to validate the crashworthiness of the structure.

Our current preference is gyroid fill, but we are looking at other patterns that might have significant benefits for other use cases. Here is a summary of the properties of a gyroid fill:

• Isotropic properties: The gyroid structure has uniform properties in all directions, which is ideal for a helmet that needs to absorb impacts from various angles.
• Continuous structure: Unlike some other patterns, the gyroid is a continuous structure without sharp corners or abrupt transitions. This can help in distributing forces more evenly throughout the helmet.
• Self-supporting: The gyroid pattern doesn’t require additional support structures during printing, which can simplify the manufacturing process.
• Excellent energy absorption: The complex, curved structure of the gyroid can provide superior energy absorption compared to simpler patterns.
• Fluid permeability: While not directly related to impact protection, the gyroid’s permeability could potentially be leveraged for ventilation or integration of other materials.
• Scalability: The gyroid pattern can be easily scaled to adjust density and mechanical properties.

This complements our theme of building test coupons for 3D printing at Numorpho Cybernetic Systems (NUMO) that are printed in conjunction with the part so that machine, material and environmental conditions are captured during the time of production to be utilized and verified for testing without the need for destroying the part. We are working on creating an equivalent “Mini-Me” test coupon that corresponds with the properties of the part, equivalent to dimensional similitude models we used to create in Computational Fluid Dynamic studies. Adaptive Element removal in Ansys Mechanical FEA package is similar to the Moving Mesh methodology I helped pioneer in STAR-CD, the CFD code that is now part of Siemens Simcenter.

This would provide a strong basis for trustworthiness in Additive Manufacturing. Thank you Grant Michel from Würth Additive Group for initiating this dialog. Recipes based their Digital Inventory System (DIS) could embed such test coupons for validation to ascertain the properties of the part down the line based on the need.

Fastway Engineering is part of our ecosystem at mHUB and we are proud to share space at this amazing innovation center.

hashtag#3dprinting, hashtag#additivemanufacturing

Edu Sciammarella, Cesar Sciammarella, Carolyn Carta, MS, PhD, James Shaw

20240901 – REDUCING SCAFFOLDING WASTE IN 3D PRINTING

Funny story about when I started writing this article. The image below initially had the title: Support Waste in 3D printing implying that the support created to scaffold the print as it is being birthed is waste, but the dual-pun meaning of the statement would have thrown them environmentalists into a tizzy!

3D FDM printing cannot happen in air and needs supports to hold the layer that they are printing once it exceeds a certain angle. Just for the four slats shown above on the left, are the amounts of supports needed to scaffold the structure.

So, we decided to change the design by updating the vent to look like the Numorpho logo and reorienting the slats so that support for the top structure is not needed. We ended up having zero supports, thus reducing the amount of waste by quite a bit!

20240904 – TWINNING ONE-SHOT PRINTING FOR THE HARD HAT

CHALLENGE: Helmets are bulky items Scaffolding

SOLUTION: Kirigami shape

PROS:

CONS: 

New filament PETG-HF

20240904 – GRACEFUL ATTENUATION TESTING

https://www.linkedin.com/feed/update/urn:li:activity:7237089575980998656/

20240928 – ONE SHOT PRINTING OF THE URBAN HARD HAT

Raise3D

SOVOL

20241218 – Smart Helmets in Peru – Thank you Arduino!

Gracias, Robby Mite Campoverde y Arduino, por mostrar los cascos inteligentes de Numorpho Cybernetic Systems (NUMO) en Perú durante su evento Tech Night. Esperamos recibir comentarios y casos de uso en entornos tan diversos e internacionales para validar nuestros cascos en la exigente tarea de garantizar la seguridad y la eficiencia operativa mediante nuestro tema CONNECT-DETECT-PROTECT para el monitoreo inteligente en entornos industriales.

Thank you Robby Mite Campoverde and Arduino for showcasing the Numorpho Cybernetic Systems (NUMO) smart helmets in Peru at your Tech Night event. We look forward to feedback and use cases in such diverse and international settings to validate our helmets for the exacting task of safety and operational efficiency using our CONNECT-DETECT-PROTECT theme for smart monitoring in industrial settings.

20250127 – Migration to Onshape and using PETG HF

• https://www.linkedin.com/posts/nitinuchil_lwm-smarthelmet-activity-7289643672214589441-H-cM?utm_source=share&utm_medium=member_desktop

Our latest Bike Helmet variant shell created using PTC Onshape CAD tool. We started the Helmet project on Autodesk Fusion360 and now migrated from Dassault Systèmes SolidWorks.

This helmet variant is our 4th lift and shift to Onshape, the others being for Hard Hats, Construction/Fire fighters and Industrial/Military helmets.

Thank you mHUB for partnering with PTC for enabling startups to utilize this tool for our design. We have found it very convenient to use because of its ubiquitous deployment online and are investigating its other features and integration with PTC tools like Windchill, Creo, Thingworx and Kepware. This progressive utilization of the different toolsets matches with our growth at Numorpho Cybernetic Systems (NUMO) to enable the creation of Large World Models (#LWM) to digitally enable and interact with the physical world.

We have also been investigating the use of different types of materials to meet the needs of the different constituencies – from PLA for prototyping to ABS, ASA, PETG and PETG-CF. This latest was created using PETG HF, a new formulation of sustainable/biodegradable material that is also quick to print.

From the source:

PETG HF is a fully optimized PETG filament designed specifically for high-speed printing. With a default printing speed that is twice as fast as standard PETG filaments, PETG HF takes your printing efficiency to new heights.

It effectively addresses common issues such as oozing and clumping associated with regular PETG, ensuring smoother and more reliable prints.

The new matte finish not only enhances the aesthetic by smoothing out uneven gloss during speed transitions but also provides a consistently uniform look.

Offering greater durability and toughness than PLA, PETG HF is the ideal choice for creating long-lasting items with an improved finish and faster production times.

#smarthelmet

SUMMARY

In this article, we outline Numorpho Cybernetic Systems’ unique approach to smart manufacturing, emphasizing the importance of crossing “t”s and dotting “i”s:

• Our approach to smart manufacturing is based on the Digital Twine World Model (DTWM) Reference Architecture, which enables the creation of smart and connected products. The DTWM approach will involve using data-driven and AI-enabled inference engines to automate activities and improve efficiency.
• Our approach involves design improvements based on ongoing user testing to ensure compliance with various governance and safety standards.
• Emphasis is on ensuring product-market fit and designing for manufacturability are key considerations, with an emphasis on low-rate production.
• Our company’s focus is on localized production and additive manufacturing techniques enables the creation of spare parts on demand, even in remote or austere environments. Our approach to smart manufacturing prioritizes both efficiency and the well-being of workers.

This article highlights Numorpho’s innovative approach to smart manufacturing and its potential to transform the industry by improving efficiency, reducing costs, and enhancing worker safety. The timestamped items demonstrate our company’s commitment to a clear and structured roadmap for the development and commercialization of its smart manufacturing solutions.

This article outlines Numorpho’s comprehensive approach to product development, commercialization, and market expansion for our smart helmet technology.

5. LINKED SOLUTIONING

NITIN UCHIL Founder, CEO & Technical Evangelist
nitin.uchil@numorpho.com

2024 mHUB HARD TECH SUMMIT

We would like to showcase our smart mobility solutions comprising of different types of helmets – industrial, construction, military, firefighter and recreational use. These have been prototyped using 3D printing and we are progressing with production using additive manufacturing technologies (3D printed casts for injection molding). Our helmets are embedded with our partner and mHUB member Arduino’s Nicla sensors to enable monitoring of environmental conditions and movement. We have programmed the ability to alert, warn and show dashboard of monitored parameters. We are adding intelligent predictive data engineering features for our products and our platform and will also showcase our approach to creating a model of a smart city (in this case it will be a 3D architecture model of Chicago) and an interactive shop floor by utilizing Augmented Reality for observing, planning, operations and anomaly detection.