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Aerodynamic testing mannequins (2024)

  

Aerodynamic testing mannequins: Revolutionizing Performance Optimization (2024)

Ross Stevens

High-performance sports demand a continuous push toward innovation,  with athletes and research teams working together to gain even the  slightest competitive edge. However, a significant challenge arises:  athletes, often pressed for time with their rigorous training schedules,  cannot dedicate long hours to sit through testing procedures.  Meanwhile, technicians and researchers require accurate, real-world data  to evaluate how equipment performs when interacting with the athlete’s  body and movement. Bridging this gap requires a solution that is both  efficient and precise.

Enter digitally crafted athlete clones—an ingenious application of 3D  scanning and printing technology. The process begins with capturing a  highly detailed scan of the athlete’s body, with or without the gear  under evaluation. This scan serves as a digital blueprint, which can be  processed and prepared for 3D printing. Once optimized, the digital file  is sent to a 3D printer, producing a physical replica of the athlete  with exceptional detail and accuracy.

The benefits extend beyond convenience. By utilizing advanced 3D  printing techniques, particularly large-scale Fused Deposition Modeling  (FDM), the mannequins are created with durability and accuracy in mind.  Every contour, muscle definition, and physical feature of the athlete is  faithfully reproduced. This level of detail ensures that the testing  results are as close to real-world conditions as possible. Additionally,  the robust materials used in FDM printing allow the mannequins to  withstand repeated handling, positioning, and exposure to testing rigs,  making them a long-term asset for research teams.

One of the most innovative aspects of Stevens’ design is the magnetic  assembly system he developed. Each 3D-printed part is equipped with  carefully positioned high strength N35 neodymium magnets, which allow  for a quick, secure, and precise connection without the need for  adhesives or complex fastening systems. This system ensures that the  individual parts fit seamlessly, maintaining the structural integrity of  the assembled model. This magnet-based approach brings significant  efficiency to the assembly process, allowing for easy disassembly and  reassembly as needed—ideal for scenarios where adjustments, refinements,  or modifications may be required during iterative testing.

  

Aerodynamic testing mannequins also open the door to rapid  prototyping and iterative design. Researchers can experiment with  modifications to equipment, such as cycling helmets, running gear, or  swimming suits, and immediately test their impact on performance.  Without the logistical challenges of coordinating athlete availability,  this streamlined approach accelerates the research and development  cycle, fostering innovation at an unprecedented pace.

Moreover, this technology has implications beyond sports. Industries  such as automotive and aerospace engineering already rely on wind tunnel  testing, and the concept of using customized mannequins could enhance  product testing in these fields. For example, creating mannequins to  represent diverse body types can help design safer, more ergonomic  vehicles or optimize personal protective equipment for various users. In  summary, digitally crafted aerodynamic testing mannequins represent a  pivotal advancement in performance research. By combining cutting-edge  3D scanning and printing technologies, they address the time constraints  of athletes while delivering precise, actionable data for researchers.  This innovation not only enhances efficiency but also fosters a new era  of experimentation, driving progress in sports and beyond.

This research project has been supported by the MADE group at Victoria University of Wellington Te Herenga Waka and the New Zealand Product Accelerator.

Software

Prusa slicer

Hardware

Custom build, large-scale, pellet extruding FDM printer, clear NatureWorks Ingeo PLA

Project Level:

Academic Research

The 3D Printery

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