As an R&D engineer, my primary responsibility was to conduct drop tests to acquire the data which formed the basis of the helmet rating project, however my role also encompassed all aspects of the testing process, including mechanical design, data analysis, and process optimisation.
With 360 total drop tests required to be completed for the project, efficiency, accuracy, and repeatability were the core project objectives. In addition to completing all tests, I was able to uphold the core project objectives through the design and implementation of 3D printed mechanical jigs which improved the positional accuracy of the helmets on the test rig while reducing individual drop test time by 40%. Overall, my contributions helped completion of the project, with the first round of ratings being disseminated.
I was able to make these contributions largely due to the application of design engineering skills and methods. Most notably, I used Human Centred Design skills to identify areas of improvement within the testing process and pose an opportunity for intervention. To find a solution, I used an iterative approach coupled with rapid prototyping, both of which are ever-present in the design engineering course, to design, make and test the jigs which ultimately brought significant benefit to the project.
