How OR3D CT used an RX Solutions scanner and Dragonfly software to visualise internal safety features on a motorbike helmet – non-destructively.  

Why look inside a helmet? 

Modern motorbike helmets hide complex internal structures – EPS liners, retention hardware, ventilation channels and multi-material shells – all designed to absorb energy and protect the rider. Traditional teardown destroys that structure and typically only lets you visualise limited amounts of the part. Industrial CT (computed tomography) lets us see everything inside, in 3D, from any angle non-destructively.  

CT gives engineers and QA teams a complete internal model for geometry checks, material continuity, assembly verification, and design review – without cutting anything open. It also enables pre-/post-impact comparisons to quantify EPS crush, micro-cracks, and hardware shifts, plus thickness mapping, porosity analysis, and dimensional metrology for traceable, supplier-to-supplier comparisons.  

What we scanned (and how)

• Object: Full-face motorbike helmet 

• Scanner: OR3D CT system from RX Solutions 

• Software: Dragonfly for post-processing, visualisation, and measurement 

• Goal: Reveal internal features to support design validation and NDT (non-destructive testing) 

What the CT revealed 

With volume rendering and material-based filtering in Dragonfly, we highlighted: 

• EPS liner geometry (uniformity, bonding continuity) 

• Retention/strap hardware (positioning, fastener presence) 

• Visor mount features (alignment, interface detail) 

• Ventilation channels (path continuity and cross-section) 

Why CT? 

• Non-destructive: Keep your prototype or production unit intact. 

• Full-field visibility: Inspect the entire internal volume, not just a cut plane. 

• Quantitative: Measure wall thicknesses, gaps, offsets, porosity and more. 

• Repeatable: Build a digital record for comparison across iterations or suppliers. 

• Shareable visuals: Clear imagery that aligns design, QA and leadership. 

Our workflow at a glance 

• Scan planning – Choose fixturing, Artefact avoidance, x-ray energy and resolution.  
• CT Scan – Run the scan on our EasyTom 230 kv from RX Solutions. 
• Reconstruction – Generate a 3D volume from 2D projections using RX Solutions XAct software. 
• Dragonfly analysis – Segmentation, volume rendering, thickness/porosity checks, and annotations. 
• Reporting & export – Screenshots, videos, 3D PDFs, or mesh export for downstream tools. 

Want to dive deeper into Dragonfly? For more information on Dragonfly, visit: https://www.or3d.co.uk/dragonfly/ 

Typical questions we can answer with helmet CT

• Are liner and shell interfaces continuous and properly seated?  

• Do vents and channels remain open after assembly?  

• Do critical regions meet thickness and tolerance targets? 

• Are there voids, inclusions, or cracks in moulded or bonded parts? 

Data deliverables you can expect 

• Annotated images/video of key features 

• Metrology extracts: wall thickness maps, distances, clearances 

• Segmentation files/meshes for CAE or documentation 

What about part size and materials? 

We routinely scan polymers, composites, light metals and small assemblies. From a wide range of industries spanning pharma, fire investigation, product design and aerospace. If you’re unsure, send a quick note with approximate dimensions, materials, and what you need to measure – we’ll recommend an approach and voxel size target that balances detail with turnaround.  

Privacy, safety, and handling 

We treat your samples and data confidentially. If you require NDAs or restricted distribution, we’ll set that up before scanning. We can also redact branding in deliverables when needed. 

Work with OR3D CT 

If this sparked ideas for your own product, we’d love to help. 

• Discover our CT services: https://www.or3d.co.uk/the-ct-centre/ct-scanning/ 

• Learn more about Dragonfly CT Software: https://www.or3d.co.uk/dragonfly/