From CAD to Show Model in Three Weeks Time
With a very short lead time, Livemap utilized CIDEAS to bring their concept to life and wow crowds at CES 2019 with their freshly designed HUD Navigation smart motorcycle helmet.
January 22, 2019
Livemap is in the process of developing the first motorcycle helmet with a permanent built in HUD that meets crash safety standards. In a fast paced market, they set their sites to reveal their latest design at CES 2019 in Las Vegas, Nevada. Once the finishing touches were complete by their industrial designers they turned to CIDEAS to make their vision into a physical, wearable show model.
Dan Williams (Head Engineer at CIDEAS) determined the best approach to produce a model that not only looked like a production helmet, but also had the functionality of one as well. This included: Adjustable vents, camera mounts, an articulating adjustable mounting hinge, and a fully polished clear 3D Printed visor. As it turns out, many of the design components needed to be tested for form fit and function, these tests were performed prior to assembly in order to validate the design and make adjustments as needed.
In all, approximately forty 3D Printed parts were used to create the final helmet. The majority of the parts were created on an SLA system utilizing Accura 25 (a general puporse material), due to its ability to create accurate models with good impact strength, good heat deflection and excellent surface finishes. SLA (Accura ClearVue) was used to produce the clear visor. The smallest and functional components were a mix between SLA, SLS (Nylon 12) and DLS (RPU70). Materials were chosen to meet the functionality needs of the gears, fixtures, connectors, and smaller flexible parts.
Each of the parts were sanded, primed and painted using a 2-stage automotive grade, color matched paint. The vector logos and markings were converted into PMS color matched decals and applied before the final clear coat, which protects them from being scuffed or scratched. The SLA clear visor was hand sanded to a near mirror finish, then protected with a UV resistant automotive clear coat (color tints may also be applied to clear parts when needed). Actual hardware was sourced for assembly and gaskets, while the foam liner was modified from an existing helmet.
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SLA was used to produce the helmet shell. Accura 25 resin was chosen due to its accuracy, durability and heat deflection. SLA parts tend to sand easier than traditional thermal plastics, which in turn reduces finishing time.
During the finishing stage, an action camera was installed, as well as the HUD projector and additional electronics for design verification and testing.
Upon completion, helmet fit checks were initiated to ensure proper foam and gasket installation. Electronics were double checked for proper fit, as well as the operation of vents and the visor.
Here the final Livemap helmet gets a final inspection prior to the client taking delivery.