A Perfect Helmet for Formula 1

Schuberth Engineering AG in Braunschweig, Germany, develops and manufactures high-tech helmets that are also preferred by many Formula 1 teams. Michael Schumacher, Rubens Barrichello, Ralf Schumacher and Nick Heidfeld rely on the individual and tailor-made helmets.

For tailor-made manufacturing, the 3D digitizing system ATOS II, a product of GOM, records the shape of the racing driver's head precisely, quickly and completely.

During a Formula 1 race, forces occur that are four times the amount of the gravitational acceleration. In order to allow for best possible protection, convenient wearing and mobility, a light, stable and compact helmet is required that is individually adapted in shape and upholstery. For this purpose, a special layered structure with a high-performance carbon fiber is used, the material of which the Formula 1 monocoque chassis are made of as well.

For optimizing the shape of the helmet, reducing its weight and improving aerodynamics, it is important to precisely and completely record the individual shape of the driver's head.

Fig. 1: ATOS digitization R. Barrichello

For measuring, the hair is pressed on the head by means of a rubber skin in order to simulate the force of pressure of the helmet. Then, the ATOS system measures the head from different directions to completely digitize it.

Fig. 2: Measuring images

In the areas of the driver's face and ears, digitization is also performed with the helmet on, in order to later transform the point cloud of the head into the coordinate system of the helmet.

Fig. 3: Special helmet: Measuring for data transformation into the coordinate system of the helmet

The result: A polygonal network which completely describes the shape of the head in detail. Then, using CAD, the helmet is constructed around the head. In case of suggestions regarding optimization - e.g. from the wind tunnel - it is possible to immediately check, if all minimum distances between helmet and head are met.

Fig. 4: Measured and helmet data

Due to the Schuberth technology and the GOM measuring system, Rubens Barrichello's helmet just weighs 1050 grams and thus is about 500 g lighter than his old helmet. That way, during a race, the muscles of the neck are essentially relieved. The slender form of the helmet results in less air resistance and better streaming to the air box. Therefore, an increased power of 10 HP is available.

We would like to thank the company Schuberth and Rubens Barrichello for the trust in the digitizing technology and the permission to share this special digitizing event.