Modular Blast Surrogate With Metamaterials for Biofidelic PPE Testing
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Solution Overview
Problem
Current blast surrogates for evaluating personal protective equipment (PPE), weapon systems, and blast environments are incomplete, costly, and require specialized knowledge to operate, failing to provide accurate high-resolution blast-pressure and acceleration data.
Innovation Solution
An anatomically correct, sensor-integrated blast surrogate using metamaterial engineering and 3D printing techniques, equipped with modular sensors for capturing high-resolution data, and designed for easy use and low-cost replacement of parts, with standardized connections for easy customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If commercialized blast surrogates (Thoracic Surrogate, WIAMan) are used, then blast-specific data can be captured, but the surrogate is incomplete and requires attachment to costly crash test dummies
Solution Approach 1:
The patent combines the blast sensor head with a complete biofidelic surrogate body into a single integrated unit. The surrogate includes anatomically correct representations of human tissues and organs with embedded sensors throughout the body, eliminating the need to attach separate sensor heads to crash test dummies. This merging creates a complete, standalone blast testing solution that captures blast-specific data while maintaining anatomical accuracy.
2Measurement precision
If costly COTS laboratory blast sensors are used, then accurate blast-pressure data can be captured, but specialized knowledge is required to operate and process data
Solution Approach 1:
The surrogate incorporates integrated electronics and processing capabilities within the surrogate itself. The system includes onboard data processing, wireless communication capabilities, and automated sensor operation, allowing the surrogate to function autonomously without requiring specialized external equipment or expert operation. The surrogate self-manages data collection, processing, and transmission, making it user-friendly while maintaining measurement accuracy.
3Reliability
If anatomically correct biofidelic surrogate is created, then accurate human blast response can be mimicked, but manufacturing complexity and cost increase
Solution Approach 1:
The patent utilizes 3D printing technology to manufacture the surrogate with precise control over material properties and structural parameters. By varying printing parameters such as layer thickness, infill density, and material composition, the surrogate achieves anatomically correct geometry and tissue-like mechanical properties. This additive manufacturing approach simplifies production of complex anatomical structures compared to traditional manufacturing methods, reducing both complexity and cost while maintaining biofidelity.
4Measurement precision
If complete surrogate with multiple sensors is used, then comprehensive blast data can be captured, but surrogate becomes less durable and more expensive
Solution Approach 1:
The surrogate is designed as a modular system with segmented components including removable sensor modules, replaceable electronic components, and separable anatomical sections. This segmentation allows individual sensor modules to be replaced after damage without requiring replacement of the entire surrogate. The modular architecture maintains comprehensive sensing capability while improving durability and reducing cost by enabling selective replacement of only the damaged components.
Data Source
AI summary
The uniqueness of the presented invention is a biofidelic, metamaterial structured, integrated with wireless sensors, modular, reusable, and anatomically accurate human surrogate (for both male and female) designed for testing and evaluation of personal protective equipment (PPE), and blast environments. Structured with metamaterials, the surrogate demonstrates a biofidelic response to blast overpressure. Metamaterials tailored for blast applications manipulate properties such as wave speed, acoustic impedance, and frequency response to match human tissues with minimized complexity. Incorporating technology from wearable blast sensors, the Blast Overpressure Body (BOB) provides high-resolution, high sampling rate, and time-synchronized simulated human blast data. Its modular design allows for easy replacement of damaged parts, alternative testing scenarios, and enhanced biofidelity, increasing flexibility and reusability. The BOB is a tool for testing, evaluating, and developing PPE and weapon systems, and for research, surveillance, and mitigation of blast exposure in military, industrial, civilian, and law enforcement contexts.