Design Engineering of High-Energy Absorbent Aircrew Helmet Using 3D Woven Structural Composite

This study investigated the effectiveness of 3D woven structural composite-based aircrew helmets comprising a 3D woven solid shell and a 3D woven honeycomb liner. This research adopted a structured sequence of steps to integrate desired aircrew helmet properties. The study involved the analysis of 3D woven structural composites through quasistatic compression and dynamic impact tests to assess their compressive strength and impact energy properties, respectively. Initially, the study focuses on optimizing the honeycomb liner by adjusting its structural parameters to improve the compressive strength. The research then delved into the critical role of impact energy, aiming to enhance load transfer to the liner for maximal impact energy absorption. Key findings highlight that the L2T2H3 honeycomb liner configuration, when combined with the OR8L3M shell, significantly improves the protective performance by exhibiting superior impact energy, cushioning properties, and compressive strength. Factors such as weave architecture, impactor geometry, impactor velocity, and face sheet thickness were found to influence the energy absorption capacity, emphasizing the importance of structural design optimization. The combined use of helmet shell and liner components demonstrated superior energy absorption capabilities compared to individual components. This combination suggests a successful approach for achieving enhanced performance in aircrew helmets. By analyzing compressive strength and impact energy, this research contributes to the ongoing efforts to enhance the performance of aircrew helmets, thereby ensuring improved safety and protection for aircrew members operating in high-risk environments.