A precision method for integrating shock sensors in the lining of sports helmets by additive manufacturing

An additive manufacturing method is presented for embedding optical fibre-based pressure sensors into the lining of sports helmets to monitor head impact in contact sports. Proof-of-concept thermoplastic polyurethane (TPU) helmet padding segments with embedded sensors are demonstrated for their sensitive shock-monitoring capabilities. The system offers a cost-effective solution for manufacturing consumer products at scale, is unobtrusive, and can be powered by medical-grade cell batteries requiring low maintenance.