Impact behavior of energy absorbing helmet liners with PA12 lattice structures: A computational study

• Methods to design new generation of energy absorbing and dissipating helmet liners with PA12 lattice structures. • Generation of high fidelity finite element lattice liner models predicting ductile to brittle transition behavior due to strain rate effects . • Linear high energy and oblique impact simulations based on a state-of-the-art helmet standard. • Helmet liners using PA12 lattice structures exhibit improvement in head protection, particularly against the rotational effects . Existing helmets have a significant but limited ability to reduce the severity of brain injury and the fatality rate during motorcycle accidents. Helmet designs with a special focus on reducing head injuries caused by rotational effects have attracted great interest in recent times. This paper uses a computational approach to study the generation of new helmet designs with lattice liners made of polyamide12 (PA12) material. Three design possibilities and three distinct unit cell topologies were used to create the liners as the energy absorbing and dissipating part of the helmet. PA12 lattice samples were additively manufactured and tested under quasi-static and dynamic compression loads. The test data, showing ductile to brittle transition due to strain-rate effects, were used to validate the finite element models of the lattices. Simulations of the linear high energy and oblique impacts on the coupled headform and liner were carried out following the state-of-the-art helmet standard ECE R22.06. The findings of this study suggest that PA12 lattice liners have an excellent capability of reducing peak rotational acceleration. Many liners can outperform the protection levels offered by existing expandable polystyrene foam liners for single impacts, but at the expense of weight. The performance of the liners can be improved by choosing the topology in such a way that the stress can be distributed through the struts. Moreover, a lattice liner having a balanced energy absorption capability and stiffness would perform better than other lattice liners.