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Leveraging 3D scanning, 3D printing and artificial intelligence in product development

Hyperganic, a company based in Munich, Germany, develops a software platform that uses artificial intelligence for the advanced design and engineering of highly complex components, structures and entire machines. Using artificial intelligence, objects can be created and sent to industrial 3D printers for output. This new manufacturing approach overcomes the limits of traditional product development and production processes.

The project

A bicycle helmet must balance design, comfort and, above all, safety. Mass production methods and traditional tools significantly limit the freedom and capabilities of both designers and production engineers. Since a handful of helmet sizes have to fit the entire spectrum of head shapes and sizes, cyclists often have difficulty finding helmets with the right fit and comfort without sacrificing safety.

3D scanning with the Go!SCAN SPARK from Creaform and screenshot in VXelements software

The Hyperganic team recently worked with partners to implement a completely new automated workflow and manufacturing process that leveraged AI-based design, 3D scanners and industrial 3D printing to produce customized helmets that could fit specific individuals.

Creaform’s 3D scanner, the Go!SCAN SPARK, which enables fast and smooth 3D scans of complex surfaces, was used to capture the dimensions of an individual’s head shape. With the help of Hyperganic Studio, the team created an app that included input information on the cyclist’s head scan, historical data on impact statistics, and an outer helmet shape.

Then, the designers got to work for the production of a customized helmet. The central part of the helmet consisted of gyroid structures, which not only helped to enhance the protection and support of the cyclist’s head but also optimized air flow for the best possible aerodynamics. For additional shock absorption and comfort, 3D-printed silicone inserts were attached to the inside of the shell.

Thanks to working with AI-optimized design software and a 3D scanner, the Hyperganic team was able to 3D print a helmet that perfectly fit the cyclists for maximum safety and comfort.