Using FFF and Topology Optimisation to Increase Crushing Strength in Equestrian Helmets

International standards ensure that equestrian helmets achieve high performance. Recently, one such standard (PAS 015) was revised to include a lateral deformation requirement, ensuring helmets can withstand the potential crushing forces associated with equestrian. This increased performance needs to be achieved against a minimal mass penalty, which is an important consumer consideration. This paper explores how shell design optimisation can improve crush resistance, validated using additive manufacturing and mechanical testing. This approach achieved a 73% increase in crush force, for only an 11% mass increase.