The ‘Moto GP’ world champion Jorge Lorenzo has left Nolan and signed a new sponsorship agreement with HJC, the world’s largest manufacturer of motorcycle crash helmets. ‘Moto GP’ is the premiere class of circuit racing, with the 250 bhp prototype bikes racing at high speeds of up to 340 kph, so safety always comes �rst. Racers have to be especially careful when choosing their helmets to protect the safety of their head, which might be a�ected the most in the event of a crash. Lorenzo stated that the helmets produced by HJC guarantee a better �t and safety thanks to their advanced manufacturing technology (process). The secret of it is in the ‘Custom-�t helmet’.

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SOLUTIONIX 3D SCANNING SOLUTION ENABLES DESIGN OF CUSTOM-FIT HELMET

SOLUTION & RESULTHJC relied on a Solutionix “Rexcan” series 3D scanner to design and manufacture helmets since 2003. The high-end scanner developed by Solutionix was selected by HJC for this project because of its speed and its ability to capture freeform surfaces, such as the human head, to an accuracy of potentially less than 10 microns. To ensure that HJC’s latest lightweight helmet, the RPHA 10, would �t Lorenzo’s head perfectly, for both comfort and in order to reduce fatigue during races, the world champion’s head was �rst scanned to create a precise 3D digital model.

The captured data is output as either a point cloud or as a polygon mesh model in the .stl format. Once the scan data model was completed it was imported into HJC’s CAD system where it could be compared with the RPHA helmet construction 3D CAD model.

With the 3D scan data model in the CAD system, the existing helmet model could then be subtly modi�ed to match the model of Lorenzo’s head, allowing for deformation of soft materials such as the foam of the inner pads. This enabled decisions to be made on pad sizes and the production of new custom-designed pads, using rapid prototyping technology or manufacturing new foam moulds. The end result was an aerodynamically e�cient helmet that �ts the current motoGP world champion ‘like a glove’ – and which may well help him retain his title at the end of the 2013 motoGP season.

Rexcan4 uses phase-shifting optical triangulation technology and employees high resolution twin CCD cameras to achieve high accuracy data, realizing less than 10um surface noise and feature error. No matter what the project scope is, Rexcan4 guarantees the best possible result whenever there is a need for high accuracy and reliability.

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SOLUTIONIX 3D SCANNING SOLUTION ENABLES DESIGN OF CUSTOM-FIT HELMET

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- Enhanced detail with High resolution twin CCD camera. - More deeper and narrower scanning area.- Flexible scanning angle.

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