Analysis
Basic FEA analysis, though on fairly complex geometry, was done using Pro/E Mechanica to ensure even stress distribution and optimal geometry.
Prototyping
Various versions of the neck brace had to be made up in order to do pre-production tests. The plastic parts were 3D printed and hand finished in the model shop in order to use it as masters for silicone tooling.
Because the production parts were to be made from a material that needed to absorb high impact forces in an accident, we needed to find a polyurethane resin with similar properties in order to help our client achieve accurate test results. Experiments with many materials were done. Finally a material was used that performed well in the 70G impact tests. We machined various iterations of the quick release system from stainless steel and aluminium in order to select the best working concept to be used on the brace.
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