Prototyping Smart Helmets: Delivering Innovation with UPTIVE’s Expertise

Client: Numorpho Cybernetic Systems
Industry: Safety Equipment/PPE
Location: Chicago, IL
Product: Safety helmets for first responders and recreational use

Numorpho is a technology-driven company dedicated to creating digital transformation solutions across industries. They’re part of the mHUB community and are known for utilizing advanced technologies like IoT, AI, and automation to enhance manufacturing processes

When developing a new smart helmet for various domains, including manufacturing, construction, and recreational activities, Numorpho sought a partner who could provide expert guidance and agile prototyping to iterate quickly.

The Challenges of Smart Helmet Prototyping

 

HP MJF 3D Printed Smart Helmet

The goal was to design a versatile smart helmet suited for multiple use cases, from industrial use on a factory floor, on-site construction activities, firefighting to bicycle riding. Numorpho needed access to a broad range of manufacturing processes, materials, and post-processing techniques to experiment and determine the ideal solution. The challenge also required fast iteration, flexibility, and educational support throughout the prototyping journey.

 

“We knew that to create a versatile, multi-purpose smart helmet, we needed a partner with extensive expertise in various manufacturing processes and materials. UPTIVE’s knowledge and experience in additive manufacturing and prototyping were crucial for us to achieve rapid iteration and optimize our design for the different use cases.” – Nitin Uchil, Numorpho CEO & Founder.

 

HP MJF 3D Printed Helmet Folded

UPTIVE’s Solutions for Engineering Smart Helmets

UPTIVE partnered with Numorpho to offer internal technology guidance, facilitate material sourcing, and provide advanced engineering solutions, including:

  • HP MJF 3D Printing with TPU for flexible lattice designs.
  • Markforged PA-6 Nylon with Carbon Fiber Reinforcement for added durability.
  • FDM Printing with ABS and PLA for rapid iteration.
  • AMT Vapor Smoothing for material finishing.
  • Injection Molding Expertise for cost and lead time considerations.
TPU lattice 3D printed helmets slats

 

“One of the best parts of what UPTIVE has done for me is that I get to work with guys like Nitin who are starting a business or launching a product, and it’s so exciting to be a part of it.” Jim Teuber, Director of Additive Market Development, UPTIVE

 

How UPTIVE & Numorpho Accelerated Smart Helmet Prototyping The Process

UPTIVE and Numorpho collaborated to explore multiple use cases and material requirements for smart helmets, such as flame retardancy and customization for helmets used in firefighting and recreational activities. Together, we tested several materials and processes, quickly pivoting based on results and feedback. This rapid prototyping process allowed Numorpho to explore various lattice designs and evaluate the performance of different materials.

 

“UPTIVE’s team was instrumental in helping us navigate through material selection, 3D printing technologies, and post-processing techniques. Their insights enabled us to refine our helmet design by balancing performance, durability, and cost-effectiveness. Thanks to their guidance, we were able to accelerate our prototyping process and move closer to the final product.”– Nitin Uchil, Numorpho CEO & Founder.

 

The Results: Fast-Track Development of Smart Helmet Prototypes 

Through UPTIVE’s additive manufacturing capabilities, Numorpho was able to fast-track the development of their smart helmet prototypes, testing a variety of designs, materials, and finishes. This accelerated feedback loop allowed them to make informed decisions quickly and push towards larger production volumes. 

The ability to iterate efficiently has brought Numorpho closer to finalizing their helmet design, positioning them for success in both the industrial and consumer markets.

Learn more about rapid prototyping with UPTIVE