Industrial workers are at significant risk of severe head injuries, for example the HSE reported 5,400 significant head injuries in 2019 with 60% of all fatalities involved a head injury. Injuries to the head are often life-changing, resulting in long-term damage such as memory loss, behavioral change and spinal damage. The economic cost of these workplace injuries was estimated to be £0.5 bn p.a. and accounted for half a million lost working days. It is likely that the problem is far worse due to poor reporting, e.g. Headway found that 52% of workers who had experienced a head injury did not report it to their manager, with only 6% of those injured seeking medical attention. In order to address the market need for an improved solution, we (HEXR Ltd) in collaboration with Imperial College London (ICL) aim to develop an ultra safe industrial helmet.

Motorcyclists are among the most vulnerable road users. Traumatic brain injury (TBI) is the most common injury that motorcyclists sustain in road traffic collisions, which can often be fatal and have life changing consequences. TBI is predominately caused by rotational motion and currently the certification standards only test for linear motion. If rotational motion could be reduced by 30%, nearly half of fatalities caused by TBI would be eliminated. Hence there is a significant opportunity to improve motorbike helmets. Our understanding of the biomechanics that cause TBI has grown significantly thanks to brain simulation and modelling. Also development of complex lattice structures using 3D printing is more affordable with a wider range of suitable energy absorbing materials. HEXR has developed the world's first custom fit bicycle helmet using 3D printing. Imperial College are the world leading experts in TBI and helmet testing. Through this 18-months industrial research project, HEXR Ltd and Imperial College London are collaborating to developing a motorbike helmet that provides the lowest chance of TBI, potentially saving thousands of lives and reducing the £15 bn economic cost of TBI to the UK economy.