BONAFIDE CERTIFICATE

Certified that this project report “COMPARATIVE STUDY OF ADDITIVE

MANUFACTURED SHIN PAD” is the bonafide work of “MOHANRAJ.H
(191101092), RAHUL.K(191101111) who carried out the project work under my
supervision.

Dr. S.P. SRINIVASAN. Mr. M. RAJKUMAR

HEAD OF THE DEPARTMENT, SUPERVISOR,

Professor Assistant Professor (SS)
Department of Mechanical Department of Mechanical
Engineering Engineering
Rajalakshmi Engineering Rajalakshmi Engineering
College College
Thandalam, Chennai. Thandalam, Chennai.

Certified that the candidate was examined in “VIVA –VOCE” Examination

held on ………………

EXTERNAL EXAMINER INTERNAL EXAMINER

I
 ACKNOWLEDGEMENT

We thank Mr. S. Megananthan, B.E., FIE., Founder & Chairman, Dr.

Thangam Meganathan., M.A., M.Phil., Ph.D., Chairperson and Mr. M.
Abhay Shankar, B.E., M.S., Vice Chairman of Rajalakshmi Institution for
providing a pleasant environment. It’s our pleasure to express my sincere
gratitude to our respected Principal Dr. S.N. Murugesan, Ph.D., for giving us
an opportunity to do project work.

We gratefully acknowledge and thank Dr. S.P. SRINIVASAN, Ph.D.,

Professor & Head, Department of Mechanical Engineering for giving his
constant Encouragement.

We thank our project coordinator Mr. N. VINOTH BABU, Associate

Professor, Department of Mechanical Engineering for his valuable suggestion
throughout this phase of the project.

We thank our project guide Mr. M. RAJKUMAR, Assistant Professor (SS),

Department of Mechanical Engineering for his valuable guidance throughout
this phase of the project.

We also express our proud thanks to all the faculty members and lab technicians
of the Mechanical Department who helped us to make this project work
successful. We also extend our sincere thanks to all our family members and
friends for their help on carrying this project success.

II
 ME19612 – INNOVATION AND DESIGN THINKING FOR
MECHANICAL ENGINEER

DEPARTMENT VISION

To provide a world class education in mechanical engineering through

innovation, excellence in teaching and research

DEPARTMENT MISSION

M1. To impart high quality technical education and prepare Mechanical

Engineers with all round knowledge of multi-disciplinary branches of
Engineering and Technology.

M2. To foster skill sets required to be a global professional for industry,

research and technology management.

M3. To provide consultancy to the neighbourhood industries. M4. To cultivate

the spirit of entrepreneurship

PROGRAMME EDUCATIONAL OBJECTIVES

PEO I

To provide students with a sound foundation in the mathematical, scientific and

engineering fundamentals necessary to formulate, analyze and solve

III
engineering problems and to prepare them for graduate studies and for
successful careers in industry.

PEO II

To impart students with skills for design, improvement and installation of

Mechanical and allied integrated systems of men and material

PEO III

To educate the students on designing the modern mechanical systems and

expose them to industrial practices for better employability and adaptability.

PEO IV

To install the values, skills, leadership and team spirit for comprehensive and
wholesome personality, to promote entrepreneurial interest among students and
to create a fervor for use of Engineering in addressing societal concerns.

PROGRAM OUTCOMES(POs)

Engineering Graduates will be able to:

1. Engineering knowledge: Apply the knowledge of mathematics, science,

engineering fundamentals, and an engineering specialisation to the solution of
complex engineering problems.

2. Problem analysis: Identify, formulate, review research literature, and

analyse complex engineering problems reaching substantiated conclusions
using first principles of mathematics, natural sciences, and engineering
sciences.

IV
 3. Design/development of solutions: Design solutions for complex
engineering problems and design system components or processes that meet the
specified needs with appropriate consideration for the public health and safety,
and the cultural, societal, and environmental considerations.

4. Conduct investigations of complex problems: Use research-based

knowledge and research methods including design of experiments, analysis and
interpretation of data, and synthesis of the information to provide valid
conclusions.

5. Modern tool usage: Create, select, and apply appropriate techniques,

resources, and modern engineering and IT tools including prediction and
modelling too complex engineering activities with an understanding of the
limitations.

6. The engineer and society: Apply reasoning informed by the contextual

knowledge to assess societal, health, safety, legal and cultural issues and the
consequent responsibilities relevant to the professional engineering practice

7. Environment and sustainability: Understand the impact of the professional

engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development.

8. Ethics: Apply ethical principles and commit to professional ethics and

responsibilities and norms of the engineering practice.

9. Individual and team work: Function effectively as an individual, and asa

member or leader in diverse teams, and in multidisciplinary settings.

10.Communication: Communicate effectively on complex engineering

activities with the engineering community and with society at large, such as,
V
being able to comprehend and write effective reports and design
documentation, make effective presentations, and give and receive clear
instructions.

11.Project management and finance: Demonstrate knowledge and

understanding of the engineering and management principles and apply these
to one’s own work, as a member and leader in a team, to manage projects and
in multidisciplinary environment

12.Life-long learning: Recognize the need for and have the preparation and
ability to engage in independent and life-long learning in the broadest context
of technological change.

PROGRAM SPECIFIC OUTCOMES (PSOs)

1. To innovate a Mechanical System which meets the desired specifications and

requirements using CAE tools.

2. To explore alternate materials for automobile, manufacturing and process

industries

3. To lead a professional career in industries or an entrepreneur by applying

Engineering and Management principles and practices. COURSE

OBJECTIVE

1. Work in a group and to identify the potential areas in the field of mechanical
Engineering.

2. Recognize the creative thinking skills to compare and contrast the several
existing solutions for the identified problem.

VI
3. Understand the project plan for creating a solution for the work identified.

4. Acquire fundamental principles of planning and carrying out the work plan
of the project through observations, discussions and decision making processes.

5. Understand how to prepare the project report and present the findings of the
work conducted.

COURSE OUTCOME:

1. Work in a group and identify the potential research areas in the field of
Mechanical Engineering.

2. Apply their creative thinking skills to Compare and contrast the several
existing solutions for the problems identified.

3. Formulate and propose a plan for creating a solution for the work identified.

4. Apply fundamental principles of planning and carrying out the work plan of
the project through observations, discussions and decision making process

5. Prepare the project report and present the findings of the work conducted.

VII
 ABSTRACT

Shin pads are part of the mandatory equipment footballers must wear so as to

prevent lesions. Most players wear commercially available shin pads made from a

variety of common materials (polypropylene, polyethylene) and high resistance

materials (glass fibre, carbon fibre, Kevlar) using traditional manufacturing

techniques. Additive manufacturing was used years ago to deliver customised rigid

shin pads, but they did not offer any significant advantage in terms of materials or

design compared to traditional shin pads. This project analyses a novel approach to

the design and manufacture of shin pads for football players that combines existing

digitisation tools, lattice structures and a multi-material additive manufacturing

device. The impact acceleration, the transmitted force to the leg and penetration were

calculated. Results were compared against two commercially available shin pads.

Results show that two of the additive manufacturing specimens tested at Ansys.

They had an acceleration reduction between 42% and 68% with respect to the

commercial shin pads. Regarding the penetration, the improvement achieved with

additive manufacturing specimens ranged from 13% to 32%, while the attenuation

and the contact times were similar

VIII
 TABLE OF CONTENTS
CHAPTER NO: CONTENT PAGE.NO:

1. INTRODUCTION 1

1.1 ABOUT DESIGN THINKING 1

1.2 GENERAL 19

1.3 HISTORY OF SHINPAD 19

1.4 SHINPAD 20
1.5 INJURIES FACED BY FOOTBALL PLAYERS 22
1.5.1 TIBIA FRACTURE 22

1.5.2 FIBULA FRACTURE 23

1.5.3 SYMPTOMS 24
1.6 OBJECTIVES 25

2. LITERATURE REVIEW 26
2.1 ARTICLES 26

2.2 SUMMARY OF LITERATURE REVIEW 27

3. WORKING METHODOLOGY 28

3.1 INTRODUCTION 28

3.2 MODELING SPECIMENS 28

3.3 MATERIAL SELECTION 29

3.3.1 POLYLACTIC ACID 29

3.3.2 ABOUT PLA 30

3.3.3 PLA FEATURE 31

IX
 3.3.3.1 NO SMELL WHEN PRINTING 31

3.3.3.2 CHEMICAL RESISTANCE 31

3.3.3.3 COMPOSTABLE 31

3.3.3.4 DEFORMABILITY AT HIGH

TEMPERATURE 31
3.3.4 POLYBUTADIENE RUBBER 31

3.3.4.1 GLASS TRANSITION

TEMPERATURE 32

3.4 MATERIAL ARE TO BE USED FOR SHINPAD 33

3.4.1 POLYETHELYNE 33
3.4.2 GLASS FIBER 33
3.4.3 CARBON FIBER 33

3.4.4 KEVLAR 35

3.5 SINGLE SCREW EXTRUDER 35

4. DESIGN AND ANALYSIS 38

4.1 DESIGN 38
4.2 PROTOTYPE OF PROJECT 39
4.3 ANALYSIS 41

5. CONCLUSION 44

REFERENCES 45

X
 LIST OF FIGURES
FIG.NO: FIGURE NAME PAGE.NO

1.1 STAGES OF DESIGN THINKING 1

1.2 FIVE STAGES OF DESIGN 2

1.3 EXAMPLE OF DESIGN INNOVATION 18

1.4 SHINPAD 21

1.5 2D MODEL 21

1.6 ANATOMICAL VIEW TIBIA FRACTURE 22

1.7 XRAY VIEW OF TIBIA FRACTURE 23

1.8 ANATOMICAL VIEW FIBULA FRACTURE 24

1.9 XRAY VIEW OF FIBULA FRACTURE 24

3.1 SCHEMATIC FIGURE 29

3.2 PLA 30

3.3 POLYBUTADIENE RUBBER 32

3.4 GLASS FIBER 34

3.5 2D CAD DIAGRAM 36

3.6 SINGLE SCREW EXTRUDER 37

4.1 3D MODEL 38

4.2 PROTOTYPE TOP VIEW 39

XI
4.3 PROTOTYPE FRONT VIEW 40

4.4 PROTOTYPE SIDE VIEW 40

4.5 ANALYSIS 41

XII
 CHAPTER 1
INTRODUCTION

1.1 About Design Thinking

Design thinking is a process for solving problems by prioritizing the

consumer's needs above all else. It relies on observing, with empathy, how people
interact with their environments, and employs an iterative, hands-on approach to
creating innovative solutions.
Design thinking gives you an opportunity to take a look at problems from a
completely different perspective. The process of design thinking allows you to look
at an existing issue in a company using creativity.
Design thinking is created not only because Tim Brown coined the word that
became a buzzword. There's a logical reason to it. Design thinking is created because
big corporation lack the ability to be creative and on extreme cases, aren't able to
create new products and services that meet unmet needs of their customers.

Principles of design thinking:

• User-centricity and empathy. Design thinking is all about finding
solutions that respond to human needs and user feedback. ...
• Collaboration
• Ideation.
• Experimentation and iteration.
• A bias towards action.
Phases of design thinking:
The design thinking process has 3 phases

1
 1. Inspiration

2. Ideation

3. Implementation.

Inspiration includes research and understanding of the problem. Ideation involves

coming up with ideas and solutions based on the research in the inspiration stage.
And implementation is launching the idea out in the market.
Stages of design thinking:
Design thinking is a non-linear, iterative process that teams use to understand users,
challenge assumptions, redefine problems and create innovative solutions to
prototype and test. Involving five phases—Empathize, Define, Ideate, Prototype and
Test—it is most useful to tackle problems that are ill-defined or unknown.

FIGURE 1.1 STAGES OF DESIGN THINKING

2
The five stages of design thinking are

FIGURE 1.2 FIVE STAGES OF DESIGN

1. Empathize—research your users' needs.

2. Define—state your users' needs and problems.

3. Ideate—challenge assumptions and create ideas.

4. Prototype—start to create solutions.

5. Test—try your solutions out

Design Thinking Stage 1: Empathy

At this stage in the design thinking methodology, designers sit down with real people
and absorb their points of view, world, and introspections without bias. Without
attempting to master empathy, designers face an uphill climb when solving human-

3
centric problems. When designing a product or service, empathy in design thinking
builds a crucial and necessary bridge between the target user or audience and the
product, project, or service being designed.some steps that are often taken during
this stage of the design thinking methodology are:
Consulting subject matter experts about their insights
• Engaging more personally with an issue to gain a better understanding
of a user’s POV
• Having in-depth conversations about the topic with other designers
• Immersing oneself in a physical environment

The empathy stage is a crucial moment in the design thinking journey, as it helps to
uncover the motivations and experiences of an audience that will ultimately be
engaging with a designer’s product. Without the empathy stage, truly solving a user
problem is nearly impossible.

Design Thinking Stage 2: Define

This stage of the process involves designers succinctly articulating the challenge or
problem they need to solve with their design. After empathizing, a designer
integrates their researched understanding into the human-centric issue at hand and
outlines the problem statement. In this stage, designers will analyze their
observations completed throughout the empathy stage, and work on synthesizing
that information. Forming a problem statement that is succinct is an important part
of this phase that ensures a human-centered approach by focusing on the end-user.
So, instead of focusing on what the company might need to do, the definition stage
of the design thinking process should help state what the user needs as a way of
defining the problem.

4
For example:

• Company-centered thinking: “We need to increase our educational

software sales by X%.”
• Human-centered thinking: “Students need great technology in order to
successfully master tech concepts.”
Design Thinking Stage 3: Ideate

The ideation stage leans heavily on the ability to invent. Designers who have
captured the human experience fully during the empathy stage set out to ideate
around creative solutions for solving the defined problem. Thinking outside the box
is the name of the game, as, during this stage, designers often don’t worry about
budget or scalability.At this point, designers should have aworkable understanding
of their user base, so this is an excellent time to get creative and not dwell too much
on limitations. An example of a popular technique in the ideation phase is an exercise
called “worst possible idea.” By inverting the search for a solution into a brainstorm
of what would not work, this process sets the design team up for success by helping
build up trust and confidence. Since no idea can technically be “wrong” in this
process, designers build up good practices of sharing their thoughts with confidence.
In this stage, the more ideas a team can put together, the more opportunity is created
to investigate and test to see if they work to solve the user’s problem.

Design Thinking Stage 4: Prototype

Without testing a newfound ideated idea, designers would have a tough time actually
solving the problem comprehensively. At this stage, the prototype of an idea is

5
required—but the ramifications are still flexible. Prototypes can be sketches, models,
or digital renders of an idea. (Professional designers and design firms usually put
budget towards prototyping something more comprehensive.) Prototyping will
usually involve the creation of small-scale, inexpensive versions of the product.
These can include specific features in order to target individual problem- solution
scenarios, and set the stage for decision-making conversations around what works
and what doesn’t. In the prototype stage, the goal is to fully understand all
ramifications or roadblocks around making the product come to life completely.
Ideally, prototyping should also uncover additional user experience problems and
set up designers with a clearer view of user behaviours, reactions, and expectations.

Design Thinking Stage 5: Test

The testing stage of the design thinking process requires real users to generate real
data. However, the final stage of design thinking is not necessarily the last thing
designers will do. Remember, design thinking is built upon a foundation of iteration,
so many designers roll out multiple prototypes to test different change factors within
their idea. Without a comprehensive testing stage, user experiences and solutions
have difficulty scaling. Testing is often an iterative process. Designers can expect to
go through a series of changes, edits, and refinements during the testing stage. For
this reason, it’s not uncommon for the testing phase to “restart” some otherdesign
thinking processes such as ideation or testing, as newfound ideas might spark
additional potential solutions that require an entirely fresh approach.

Advantages of Design Thinking

1. It is comprehensive & holistic:

6
Design thinking includes the number of individuals from a wide range of offices.
With more and more number of contributions from different individuals with
changing degrees of abilities and expertise, more points of view for handling the
current problem occur in design thinking.
2. It is logical and scientific:

Such type of thinking requires investigating how audiences connect with items and
looking at the conditions in which they will utilize the product or service. This way
of thinking involves exploring questionable components for uncovering inventive
methodologies for solving problems.
3. It is non-linear:

The designing team can utilize the outcomes at each step to survey and analyze their
notions, lessons, and results because of the non-linearity of design thinking. This
reclassifies the issue and opens doors to new experiences that can further be utilized
for showing up better choices.
4. It is for everyone:

This form of thinking is best-suited for UX/UI companies, freelancers, inventive

employees, leaders, managers, and all others who wish to take care of a wide scope
of issues.
5. It empowers testing:

Design thinking suggests performing a wide range of testing for reexamining

solutions again and again.

Disadvantages of Design Thinking

1. Design Thinking Has an Image Problem. ...

2. Some See Design Thinking as a Linear Process.

7
 3. Some View Design Thinking as a Glorified 2-3 Day Workshop. ...

4. People Want Human-Centric Outputs Without Human Inputs. ...

5. Misalignment is a Risk to Every Design Thinking Project.

Examples of Design Innovation

8
16

9
17
FIGURE 1.3 EXAMPLE OF DESIGN INNOVATION

18
1.2GENERAL:

Football is one of the most popular sports worldwide with more than 265
million male and female players. Player injuries mostly occur in the lower
extremities (87%), especially in the thigh, knee, ankle and hip. Fractures represent
2%–11% of all football injuries and lower extremity fractures account for 30%–
33% of all fractures, which occur while tackling (14.1%), being tackled (32.9%)
or in a 50/50 tackle situation (50%). In a study by Cattermole et al.,3 57% of tibia
fractures were due to a three-point bending.

1.3 HISTORY OF SHINPAD:

However, within the literature it is not clear what type of impact is

necessary to fracture a tibia, as both high-energy and low energy impacts can be
associated with this type of injury. There is also lack of unanimity regarding the
peak force needed to fracture the tibia. Shin pads have been evaluated in the
literature through a variety of tests. Phillipens and Wismans evaluated nine
different shin pads and found that pads reduced the peak force by 28%–53%.
Similarly, Biretal used a pendulum impact apparatus and showed that peak impact
forces were reduced between 40% and 77% when the pads were used. Lees and
Cooper obtained a reduction in peak impact force of between 40% and 60% and
that the level of protection showed no correlation to the price of the pad. Francisco
et al tested shin pads made of plastic, fibreglass and Kevlar by dropping an
impactor from different heights. All the pads provided protection at all of the
impactor’s drop heights. Ankrah and Mills carried out a falling striker impact test
showing that shin pads on the market vary considerably in their ability to
distribute load. Finally, Tatar evaluated three polypropylene and two carbon fibre
shin pads under low (0.8 kN) and high (3 kN) severity impacts. Similar to other

19
authors, they found that pads decreased the risk of serious injuries, but
commercially available polypropylene-based shin pads did not provide sufficient
protection against high impact forces. All these studies agree that shin pads are
effective, but despite that fact that the incidence of football leg injuries decreased
significantly since the introduction of the shin pad in 1990 (1996–2000: 220%;
2001–2005: 225%), the effectiveness of shin pads against, for instance, tibia
fracture is still under discussion.

1.4 SHINPAD

Shin pads are governed by the British Standard 13061:2009, which

subjects the shin pads to various tests. However, according to various authors,
these tests are aimed at reducing the severity of laceration, contusion and skin
puncture caused by impacts rather than preventing tibia fractures. The process of
shin pads design should take into account parameters like manufacturing material
and shape to produce a product that will prevent leg injuries. Most commercially
available shin pads have a near-cylindrical shape, typically manufactured with a
rigid outer cover and a soft inner shell. For the outer cover, polypropylene or
polyethylene is mainly used, although materials such as glass fibre, carbon fibre
or Kevlar have also been introduced, especially for shin pads for professional
football players. For the inner shell, the material is a low-density polymer with
high shock absorption and biocompatible properties, like ethylene vinyl acetate
(EVA) foam.

20
 Fig1.4 SHINPAD

Fig 1.5 2D-MODEL

21
1.5 INJURIES FACED BY FOOTBALL PLAYERS

1.5.1 TIBIA FRACTURE:

The shine bone or Tibia is the long bone located in the lower leg between the
knee and foot. Tibia fracture are are common and usually caused by an injury or
repetitive strain on the bone. Tibia fracture refers to any track or breaks in the
tibia bone

• A fractured tibia often occurs with other kind of tissue damage to the
nearby muscles or ligaments.

• It may be transverse fracture, means the crack is horizontal across the bone,
or oblique, meaning the crack is at an angle.

Fig 1.6 ANATOMICAL VIEW

22
 Fig1.7 X-RAY VIEW

1.5.2 FIBULA FRACTURE:

A fibula fracture is used to describe a break in the fibula bone. A forceful

impact, such as landing after a high jump or any impact to the outer aspect to the
leg, can cause a fracture. Even rolling or spraining an angle puts stress on the
fibula bone. Which can lead to a fracture.

23
 Fig1.8 ANATOMICAL VIEW

Fig 1.9 X-RAY VEIW

1.5.3 SYMPTOMS:

Pain, swelling and tenderness are some of the most common signs and
symptoms of a fractured fibula

24
  Tender to the touch.

 Visible deformity.

 Bleeding and bruising in the leg.

IMPACT RANGE DUE FRACTURE:

The fracture of reported in the literature at impact of:

 2927N

95% of the tibial fracture were transverse or short oblique and were
caused by impact during a tackle.

1.6 OBJECTIVES:

• Additive manufactured shin pads with reduced risk of tibia related injuries and
fractures.

• An appropriate design approach with lattice structure can deliver shin pad with
better performance.

• Professional players demand of customized pad with exact anthropometry of

their leg is feasible

25
 CHAPTER 2

LITERATURE REVIEW

2.1 ARTICLES:

1. MSN, BSN, WHNP-BC; April 27,2018:

In this we learnt the Introduction to tibia and fibula fracture. Tibia and
fibula fracture are characterized as either low-energy or high energy. L ow
energy, nondisplaced fractures, sometimes called toddler’s, occur from minor
falls and twisting injuries. High energy fracture, such as those caused by serios
car accidents or major falls, are more common in older children. From this we
observed and studied about the tibia and fibula fracture.

2. Knee surg sports traumatol arthrosc 1999;7(4):262-266:

This paper refers that how the tibia and fibula fracture in soccer players.
Injuries typically occurred in young, competitive athletes during game situation.
Injuries were associated with a high incidence of major complications (12 out of
31, 39%), especially in concurrent tibia and fibula fractures (8 out of 15, 50%).
These findings suggest that lower leg fractures in soccer players are serious
injuries, often necessitating a prolonged recovery time. These are the effect of
tibia and fibula fracture on soccer players.

3.Prosthetics-Orthotics and Rehabilitation Center 2014; 120 – 127:

In this we can observed the study of material used in conventional

shinpads. For peak force and impulse, the carbon fiber shin guard provided better
protection than all the other.

26
4.Sports English;2003;6;207-220:

Football shin guards were evaluated against a kick from a studded boot.
The bending stiffness of their shells, and their response when impacted by a stud,
were assessed using finite element analysis (FEA) and determined
experimentally. A test rig was constructed with the leg muscle simulated by
flexible foam, with the force distribution along the tibia and to the lateral muscle
measured using flexible force sensors. High-speed photography confirmed
deformation mechanisms predicted by FEA. Load spreading from the stud impact
site correlated with the guard shell bending stiffness. The best guards use shells
of complex shape to increase their transverse bending stiffness. From this
Checking the effectiveness of shinpad by performing direct stud impacts.

5. J Sports Engineering and Technology; 2019; Vol-233(I) 160-169:

This project analyses a novel approach to the design and manufacture of

shin pads for football players that combines existing digitisation tools, lattice
structures and a multi-material additive manufacturing device. A total of 24
different additive manufacturing geometries were evaluated using a customised
rig where a 1-kg impactor was released from several heights (100–400 mm). The
impact acceleration, the transmitted force to the leg and penetration were
calculated. Results were compared against two commercially available shin pads.
From this we learnt the comparing the quality of various shin pads.

2.2 SUMMARY OF LITERATURE REVIEW:

From the above literature, there is no change in design which plays a major
role. As mentioned in the above literature, all the authors tends to make the
shinpad modern but not customer friendly. The intend of the literature review is
to provide an overview and transparency into the type of source used so others
may build off the knowledge assembled.

27
 CHAPTER 3
WORKING METHODOLOGY

3.1 INTRODUCTION:

The entire methodology was divided into six phases; each one involved
several steps. The process started with the modelling of several cylindrical
specimens that feature a lattice structure for shock absorption. These specimens
were modelled considering the advantages and limitations of the later AM
process. Then, specimens were printed using a multi-material AM printer to
print the lattice structure in a shock-absorbing rubber-like material. Next,
specimens were evaluated using a stud impact test and their performance was
compared against two commercial shin pads. Later, the digitisation of the
patient’s legs was performed in order to obtain the virtual mesh of the leg. Next,
a CAD model of the basic shape of the shin pad based on the virtual leg was
created. Finally, the design incorporating the best lattice structure from the stud
test was 3D printed.

3.2 MODELLING SPECIMENS:

A total of 24 specimens were modelled, manufactured and tested in order

to analyse and determine an appropriate lattice structure that maintains a
reasonable level of performance with respect to commercial shin pads. Since most
shin pads have a near-cylindrical shape,13 several cylindrical specimens were
modelled in CREO 3.0. The inner diameter of each specimen was set to 110 mm
after inspecting the geometry of commercial shin pads used as reference in this
project for comparison purposes. Their length and width were set to 50 mm. Each
specimen had three parts: an inner, a middle and an outer shell . The inner and
outer shells are supposed to be rigid, while the middle shell is supposed to work
as the shock-absorbing geometry. This last geometry was modelled with a lattice
structure of cylindrical bars. The thickness of the inner and the lattice was fixed

28
to 1 and 5 mm, respectively, while the outer shell thickness (e1), diameter of the
cylindrical columns (vd), spacing between two adjacent columns (hs) and
presence or absence of horizontal connections among columns (hd) were the
variable parameters. Several holes were crated in the inner shell, not only to
facilitate the removal of the support material from the AM process but also to
reduce the weight and increase perspiration of the future shin pad. This step ended
with all the specimens exported to STL files for the printing process.

FIG 3.1 SCHEMATIC FIGURE

3.3 MATERIAL SELECTION:

3.3.1 POLYLACTIC ACID(PLA):

Polylactic acid (PLA) is a type of plastic that is used in building models

and prototypes of solid objects and components. It is a thermoplastic polyester
that serves as the raw material in 3-D printing or additive manufacturing
processes and applications. Polylactic acid is also known as polylactide acid.
PLA is a thermoplastic monomer derived from renewable, organic sources such
as corn starch or sugar cane. Using biomass resources makes PLA production

29
different from most plastics, which are produced using fossil fuels through the
distillation and polymerization of petroleum.

FIG 3.2 PLA

3.3.2 ABOUT PLA:

We must use PLA whenever the priority of our piece is the quality of finish.
In addition to its properties such as rapid cooling, PLA is marketed in a much
wider range of colours than other materials. If we need incredible colours, shiny,
with glitter, with multi colour particles or with any other fantasy finish, PLA is
undoubtedly the choice.

On the other hand, PLA is by no means a brittle material, even though it is more
fragile than ABS or PETG. This is why PLA remains a viable alternative for
pieces that require moderate resistance and especially wherever the piece must be
as rigid as possible.

30
If we need exotic materials, such as wood fibers, surely the filaments we will
find are formulated with a PLA base, so, even without knowing it, when we print
then we will be printing in PLA.

3.3.3 PLA FEATURES:

3.3.3.1 NO SMELL WHEN PRINTING:

You may have noticed that PLA does not smell when it is printed, which
is very convenient. Besides the convenience, this means that it is not emitting
some of the toxic particles that other materials, such as ABS, do.

3.3.3.2 CHEMICAL RESISTANCE:

PLA is a very stable material, and so it is quite resistant to chemicals such

as acetones or alcohols. Very powerful solvents such as dichloromethane are
required to dissolve PLA, so everyday chemicals will not make a dent in PLA.

3.3.3.3 COMPOSTABLE:

PLA can be composted (turned into fertilizer or manure) by being in a hot

(usually above 60 degrees) and very humid environment.

3.3.3.4 DEFORMABILITY AT HIGH TEMPERATURES:

PLA deforms when temperatures exceed 60-70 degrees, so one way to
make very original parts is to heat them (with a heat gun or by putting them on
the printer bed for a while) and deform them carefully to give them a curious
shape. If you think it is an interesting idea do not hesitate to leave us a comment
so that we can show you what can be achieved with this technique.

3.3.4 POLYBUTADIENE RUBBER:

Polybutadiene [butadiene rubber BR] is a synthetic rubber. Polybutadiene

rubber is a polymer formed from the polymerization of the monomer 1,3-
butadiene. Polybutadiene has a high resistance to wear and is used especially in

31
the manufacture of tires, which consumes about 70% of the production. Another
25% is used as an additive to improve the toughness (impact resistance) of
plastics such as polystyrene and acrylonitrile butadiene styrene (ABS).

FIG 3.3 POLYBUTADIENE RUBBER

3.3.4.1 GLASS TRANSITION TEMPERATURE:

Polybutadiene has excellent abrasion resistance (good tread wear), low

hysteresis loss, high elasticity, and low rolling resistance due to its low glass
transition temperature (Tg), typically <−90 °C.

32
3.4 MATERIALS ARE TO BE USED FOR SHINPAD

3.4.1 POLYETHELYNE:

Polyethylene fabric is a thermoplastic polymer made of different

crystalline structures from petroleum-based plastics. It is the most widely used
plastic today. Polyethylene is an olefin fiber, a synthetic fiber made from a
polyolefin, similar to polypropylene. There are various packaging options in the
market, but one of the most commonly used packaging material is polyethylene.
It is the most durable type of plastic available today owing to its properties of
chemically resistant and low in cost.

USES:

Polypropylene fabric is a textile made from PP, which is a thermoplastic

polymer commonly used in food packaging, plastic furniture, films, automotive
parts, and medical devices. This plastic is a linear hydrocarbon polymer, and it is
one of the most popular plastics due to its low cost and easy manufacturability.

DISADVANTAGE:

Polyethylene is mainly extracted from petroleum or natural gas, of which

there is a finite amount. Producing polyethylene takes a large amount of energy
and also leads to high emissions of carbon dioxide, a greenhouse gas contributing
to global warming and climate change

3.4.2 GLASS FIBER:

Glass fibre is a material made up of several fine fibres of glass. The product
is one of the most versatile industrial materials known today. It has comparable
mechanical properties to other fibres such as carbon fibre and polymers. A
fiberglass is a form of fiber-reinforced plastic where glass fiber is the reinforced
plastic. This is the reason perhaps why fiberglass is also known as glass reinforced
33
plastic or glass fiber reinforced plastic. The glass fiber is usually flattened into a
sheet, randomly arranged or woven into a fabric.

FIG 3.4 GLASS FIBER(chopped)

DISADVANTAGE:

Fibre glass last a long time, it can be coloured, shiny or dull. It is low
maintenance, anti-magnetic, fire resistant, good electrical insulator and
weatherproof. The disadvantages is that it needs to be re-gel coated about every
five years and can result in airborne fibres which may be an issue to asthma
sufferers.

3.4.3 CARBON FIBER:

Carbon Fiber is a polymer and is sometimes known as graphite fiber. It is

a very strong material that is also very lightweight. Carbon fiber is five-times
stronger than steel and twice as stiff. Though carbon fiber is stronger and stiffer
than steel, it is lighter than steel; making it the ideal manufacturing material for
many parts. These are just a few reasons why carbon fiber is favored by engineers
and designers for manufacturing.

34
USES:

It is a strong, stiff, lightweight material that has the potential to replace

steel and is popularly used in specialized, high-performance products like
aircrafts, racecars and sporting equipment.

DISADVANTAGES:

• Disadvantages of carbon fiber composite production with hot-press

forming:

• High costs of production implementation.

• Difficult to make elements having so-called negative angles.

3.4.4 KEVLAR:

Kevlar is a heat-resistant and strong synthetic fiber, related to other aramids

such as Nomex and Technora.Kevlar has many applications, ranging from bicycle
tires and racing sails to bulletproof vests, all due to its high tensile strength-to-
weight ratio.

USES:

Kevlar is a type of aramid fiber. It is woven into textile materials and is

extremely strong and lightweight, with resistance toward corrosion and heat. It is
used in vast applications such as aerospace engineering (such as the body of the
aircraft), body armor, bulletproof vests, car brakes, and boats.

3.5 SINGLE SCREW EXTRUDER:

A single screw extruder is a machine used to form a plastic product into

the required shape. The machine heats the plastic raw material (eg: PVC) to its
melting point, after which it is pushed through a die that gives the material its

35
shape. This machine is used to mix the glass fiber and PLA together in the ratio
5:9 to form combination of glass fiber.

Fig 3.5 2D CAD Drawing

36
Fig 3.6 single screw extruder - Isometric view

37
 CHAPTER 4

DESIGN AND ANALYSIS

4.1 DESIGN:

FIG 4.1 3D-MODEL

38
4.2 PROTOTYPE OF PROJECT

FIG 4.2 PROTOTYPE OF PROJECT

39
FIG 4.3 FRONT VIEW

FIG 4.4 SIDE VIEW

40
4.3 ANALYSIS:

FIG 4.5 ANALYSIS

41
MECHANICAL PROPERTIES:

POLYETHELENE:
Density : 952 kg\m3
Young’s modulus : 1.07*109
Poison ratio : 0.43
Shear modulus : 225MPa
Thermal expansion coefficient : 1.98-4 strain
GLASS FIBER:
Density :2.44 g/cm3
Young’s modulus : 72 GPa
Poison ratio : 0.21
Shear modulus :30 GPa

calculation:
F = m.a
Where,
F = force
m= mass
a = accleration

Assume that m = normal person body weight 72kg [1]

a = 0.278 m/s
therefore,
F = 72*9.81*0.278
F = 196.35 N

42
RESULT:

• In the ANSYS report the material used is polyethelene and glass fiber.

• During analysis we obtained the 0.1227 mm as deformation.

• The mechanical properties are taken from the vinidex.com.

• The minimum deformation is obtained in the bottom of the pad.

• The maximum deformation is obtained in the top corner of the pad.

43
 CHAPTER 5
CONCULUSION

• We conclude that our project are useful to the football players. This project
help the player to play more safely, with our safely features, we can reduce
the risk of the player.

• Result from the testing phase are shown in the fig 4.5. These pads with a
thicker outer shell were characterised by supporting higher impact without
fracturing, independent of the lattice structure.

• The result indicate that the force transmitted from the impact to the player’s
leg is lower.

• The minimum deformation is obtained in the bottom of the pad. The

maximum deformation is obtained in the top corner of the pad. Therefore,
we create this project is help the player with more safety.

44
REFERENCES:

[1] MSN, BSN, WHNP-BC; April 27,2018.

[2] Kunz M. 265 million playing football. FIFA Magazine, July 2007,
https://www.fifa.com/mm/document/fifafacts/
bcoffsurv/emaga_9384_10704.pdf.
[3] Prosthetics-Orthotics and Rehabilitation Center 2014; 120 – 127.

[4] Sports English;2003;6;207-220:

[5] J Sports Engineering and Technology; 2019; Vol-233(I) 160-169:

[6] Boden BP, Lohnes JH, Nunley JA, et al. Tibia and fibula fractures in soccer
players. Knee Surg Sports Traumatol Arthrosc 1999; 7(4): 262–266.
[7] Kramer M, Burrow K and Heger A. Fracture mechanism of lower legs under
impact load. In: Proceedings of the 17th STAPP car crash conference, Coronado,
CA, 17–19 November 1973, pp. 81–101, Warrendale, PA: Society of Automotive
Engineers.
[8] British Standard 13061:2009. Protective clothing: shin guards for association
football players: requirements and test methods.
[9] Boden BP. Leg injuries and shin guards. Clin Sports Med 1998; 17: 769–777.
[10] Ankrah S and Mills NJ. Performance of football shin guards for direct stud
impacts. Sports Eng 2003; 6: 207– 220.
[11] Tatar Y, Ramazanoglu N, Camliguney AF, et al. The effectiveness of shin
guards used by football players. J Sports Sci Med 2014; 13: 120–127
[12] Lees A and Cooper S. The shock attenuation characteristics of soccer shin
guards. London: E & FN Spon, 1995, pp.130–135.

45