Voronoi Structures Maximize Energy Absorption in Bicycle Helmets

Bionics Voronoi Structures Maximize Energy Absorption in Bicycle Helmets

2026-11-03 Source: HSBI | Translated by AI 1 min Reading Time

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Mechanical engineering students have developed a bicycle helmet that draws on principles found in nature: Through the strategic use of so-called Voronoi structures in combination with the material TPU, impact energy is absorbed so efficiently that the bionic helmet outperforms standard commercially available models in initial tests.

An irregular yet honeycomb-like Voronoi structure is highly effective at absorbing the applied force.(Source: J. Wunder/HSBI) — An irregular yet honeycomb-like Voronoi structure is highly effective at absorbing the applied force.
(Source: J. Wunder/HSBI)

Nature often provides the best design principles: turtle shells and bones absorb impact energy extremely efficiently without breaking. As part of a hands-on project at the HSBI’s Minden campus (Germany), mechanical engineering students, under the guidance of Prof. Dr. Andreas Tenzler, analyzed these bionic concepts and translated them into a technical product. The goal: a 3D-printed bicycle helmet whose structure maximizes energy absorption while keeping the weight low.

Focus on CAD Limitations and Material Selection

During the development process, honeycomb, tree, and Voronoi structures quickly emerged as the most promising geometries for shock absorption. However, the design posed challenges for the team: “Biological, organic structures are technically difficult to describe because of their irregularity. Conventional CAD programs are often overwhelmed by this,” explains Prof. Tenzler. The students therefore had to familiarize themselves with alternative software for modeling bionic geometries.
In addition, they had to determine the optimal balance between fill density, web thickness, and material. Through iterative design and testing cycles, the significant influence of the material became apparent: While hard plastics such as PLA (polylactide) proved unsuitable for the required deformation, TPU (thermoplastic polyurethane) delivered the desired properties.

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The students had to apply principles and phenomena from nature to technical applications and chose to design a bicycle helmet.(Source: J. Wunder/HSBI)

The students designed, built, tested, modified, rebuilt, tested again, modified again, and so on.(Source: J. Wunder/HSBI)

Honeycomb, tree, and Voronoi structures are particularly effective at absorbing shocks: Thanks to their unique geometry, they are elastic enough to deform and better distribute the impact energy.(Source: J. Wunder/HSBI)

Various structures, web thicknesses, fill levels, and materials had to be combined and tested.(Source: J. Wunder/HSBI)

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Better Shock Absorption than Standard Helmets

The final combination of an irregular, honeycomb-like Voronoi structure and TPU was then subjected to stress tests (simulating real-world bicycle crashes) in compression and drop test machines. The result: The bionic geometry not only absorbs the impact force exceptionally well, but the helmet also provides even better protection against impact forces than comparable mass-produced models available on the market.

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Date: 08.12.2025

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