Solutionix 3D Scanning Solution Enables Design of Custom-Fit Helmet

Bristol, UK. 7 June, 2013. Solutionix, the leading developer and manufacturer of structured light 3D scanning solutions, announced that HJC, the world’s largest manufacturer of motorcycle crash helmets, relied on a Solutionix Rexcan 3D scanner to provide the 3D digital data that it required to design and manufacture a custom-fit helmet for reigning motoGP world champion Jorge Lorenzo to wear in the 2013 motoGP season.

To ensure that HJC’s latest lightweight helmet, the RPHA 10, would fit Lorenzo’s head perfectly, for both comfort and in order to reduce fatigue during races, the world champion’s head was scanned to create a precise 3D digital model. This enabled the reverse engineering of custom padding for the interior of the helmet and also provided fitting data for the outer shell size and a model for HJC’s ergonomic library.

The Solutionix scanner, which uses structured light as opposed to a laser as found in many other 3D scanners, was selected by HJC for this project, as well as for a variety of other reverse engineering and quality inspection applications, because of its speed and its ability to capture freeform surfaces, such as the human head, to an accuracy of potentially less than 10 microns. The captured data is output as either a point cloud or as a polygon mesh model in the .stl format.

Once the scan data model was completed it was imported into HJC’s CAD system where it could be compared with the RPHA helmet construction 3D CAD model.

Robert Keogh, regional manager, EMEA, Solutionix, explains, “A motorcycle helmet relies on a good fit in order for it not to move on the head either at high speed – over 340kph (210mph) in the case of motoGP – or particularly in the event of a crash, when the shell and internal padding are designed to deform and absorb impact in a precisely controlled manner”.

With the 3D scan data model in the CAD system, the existing helmet model could then be subtly modified to match the model of Lorenzo’s head, allowing for deformation of soft materials such as the foam of the inner pads. This enabled decisions to be made on pad sizes and the production of new custom-designed pads, using rapid prototyping technology or manufacturing new foam moulds.

The end result was an aerodynamically efficient helmet that fits the current motoGP world champion ‘like a glove’ – and which may well help him retain his title at the end of the 2013 motoGP season.

Solutionix Corp.

in 2000 and headquartered in Korea, with its EMEA office based in the UK, Solutionix Corp is a developer and manufacturer of high-performance structured-light 3D scanning systems for reverse engineering and quality inspection applications in the industrial and manufacturing market sectors as well as in dental CAD/CAM applications.

The company’s Rexcan-DS2, Rexcan-CS, Rexcan-3 and Rexcan-4 3D scanning systems are based on phase-shifting optical triangulation technology and use twin high-resolution CCD cameras to capture high accuracy 3D scan data of physical objects measuring from less than 1cm across up to 1.5m, diagonally, in a single shot. Through the scanners’ accuracy and compatibility with photogrammetry systems, large objects can be accurately captured in multiple shots.

Sales and technical support services are provided worldwide both directly and through a growing network of distributors and value-added resellers. Find out more at:

For further information contact:

Robert Keogh, Tel: +44 (0) 7767 777615; Email Contact or

Neil McLeod, Tel: +44 (0)1666 504293, Email Contact


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