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