Protective Headgear for Neurosurgical Patients

Year Submitted: 2025
Published Date: 06 May 2025

Tags: Applied/Translational Research, Qualitative Research, Quality Improvement

About this Content

Aims

This project aims to design and create a prototype for a protective helmet that can be worn after brain surgery (specifically craniectomies), fulfilling the core criteria of being both protective and inconspicuous at the same time.

Background

Surgeries involving the penetration of the cranium are performed routinely for a wide variety of diagnosis from trauma to tumours and aneurysms. Following open brain surgery, patients often then require specialised care for repercussions that may persist long after the initial insult. Decompressive craniectomies are not uncommon in the Department of Neurosurgery, leaving patients with an often-disfiguring wound on the skull in exchange for a life-saving procedure. Cranioplasties can be performed a few months after the initial surgery to correct the defect with an artificial bone flap, but this is an elective procedure, and the implant alone can be very costly. However, for those who have not undergone a cranioplasty, the skull defect can result in social isolation from fear of stigmatisation when leaving the home, or from fear of inadequate protection of the exposed soft tissue. Patients who have undergone brain surgery, as well as their caregivers, have reported increased incidences of minor head injuries, falls,nand seizures post operatively. There is currently no option for our patients in the Singapore market, and options available overseas are often bulky, expensive or both.

Methods

A pre-implementation survey was first conducted with patients and their families to understand what consumers take into consideration when deciding on whether to obtain a protective headgear. Questions were targeted at discerning factors that made people more hesitant about leaving their homes after brain surgery, interest in procuring protective headgear, factors affecting choice of headgear, as well as amount willing to be spent on protective headgear. The survey was spread both online, as well as hardcopy format during head injury support group meetings. A separate survey was also sent out amongst the general public and healthcare professionals to assess the above factors from a non-patient perspective. Concurrently, market research into what is currently available to patients in other countries, as well as their implementation strategies within the healthcare system, was analysed. Following the completion of the research phase, a multidisciplinary team of doctors, orthotists, designers and engineers will work together to design a form of protective headgear aimed at offering adequate protection to the more vulnerable head while maintaining a level of aesthetic to remain inconspicuous. The teams aim was to create a workable design within the first 2 to 3 months, and thereafter select appropriate materials for stress testing.

Results

We were able to complete the POC for the protective headgear. Our strength testing as analysed using Solidworks shows the design to be safe for use and structurally tested to a factor of 2 times the human skull. The overall weight was below 150grams and deemed suitable for the next phase in development. Further development in the material selection and manufacturing processes is needed to improve cost effectiveness for the patients. Our protective headgear seeks to fill a gap in the current available healthcare field, addressing not only the safety of our patients, but their psychological and emotional wellbeing.

Conclusion

The protective headgear POC was achieve and followed closely a biomimicry concept of a hexagonal design to provide strength and weight benefits. We successfully 3D printed the final design and were able to use this to pitch for further funds to continue work on the project.

Lessons Learnt

Collaboration with the right partners is key to a positive outcome. Working with external bodies such as university students is challenging given the students need to complete the project to graduate and may rush the end result.

Additional Information

We managed to work with a student from SIT Engineering on this project, reducing the cost of the project to $0. He was supported by the professors at the university to ensure accurate and timely research assistance and design.

Keywords

Helmets, craniotomy, protection, wearables

Innovators' Details

Connect with this contributor!

Trevor Binedell - Trevor_binedell@ttsh.com.sg ↗ (opens in new tab)

Project Attachment