Reproducible Process of 3D Representative Head Model for Helmet Design -Focusing on Korean School-Age Children-

This study aimed to develop a reproducible 3D head model for helmet design, specifically tailored to the unique head shape characteristics of Korean school-age children. The research addressed the limitations of the EN 960 standard and sought to create a head sizing system that would improve fit and safety for this demographic. The head dimensions of 3,344 Korean children aged 7 to 13 were comparatively analyzed with the EN 960 headform standard. Discrepancies in head size and morphology were identified. A representative head size of 535 mm in circumference was selected, and ten 3D head scans matching this average were combined to create a new representative model. The study employed a four-step process to ensure the reproducibility of the 3D model. The new 3D model for size code 535 exhibited a 7.6 mm larger breadth and an 8.4 mm smaller length compared to the EN 960 standard. This new sizing system increased population coverage from 69.3% to 91.4%, ensuring a more accurate and ergonomic fit for Korean children. This new head model offers a reliable method for designing ergonomically optimized safety equipment, and its reproducible process can be adapted for other populations.