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Project

PCM Helmet Cooling System

Early thermal and mechanical subsystem concept using paraffin wax PCM, CAD geometry, ANSYS-style mesh visuals, material packaging, and helmet comfort constraints.

Early-stage helmet cooling concept using paraffin wax phase-change material, CAD geometry, mesh visuals, material/prototype images, packaging constraints, and user-comfort context.

  • Thermal Design
  • PCM
  • CAD
  • Mesh Studies
  • Material Packaging
  • User Comfort
PCM Helmet Cooling System visual 1
Project imageCoarse mesh volume for PCM cooling geometry
01

Overview

This project explored a helmet cooling concept using paraffin wax phase-change material as a thermal subsystem.

The page uses CAD, mesh, material, prototype, and selected report visuals to discuss thermal packaging, mechanical fit, user comfort, and early-stage design reasoning.

02

Problem

Helmet cooling needs to manage heat while fitting safely and practically into helmet-related geometry.

The work combines thermal reasoning, PCM material choice, mechanical packaging, user comfort, manufacturability, and mesh-based design material at the concept stage.

03

My Role

  • Worked with CAD, mesh, prototype, material, and documentation for the PCM concept
  • Prepared public-facing visuals from images and report material
  • Organised the project as an early-stage thermal and mechanical subsystem case study
04

Process

  1. Thermal concept

    The design explored paraffin wax phase-change material as a way to absorb heat within helmet-related packaging, fit, and user-comfort constraints.

  2. CAD and mesh material

    CAD and ANSYS-style mesh visuals show how geometry and simulation-style outputs were used to reason about the subsystem and communicate design trade-offs.

  3. Material and packaging review

    Prototype/material visuals and selected figures show how PCM selection, enclosure geometry, manufacturability, and user constraints were recorded for the project page.

05

Key Decisions

PCM packaging

The project connects heat-management intent, paraffin wax PCM, mechanical fit, containment, user context, and manufacturability.

Mesh-based design material

CAD, mesh, material, prototype, and report visuals are presented together so the subsystem can be reviewed as an early design concept.

06

Project Material

Selected project material used to show CAD, component, prototype, or documentation details.

PCM Helmet Cooling System visual 1
Fig. 01Coarse mesh volume for PCM cooling geometry
PCM Helmet Cooling System visual 2
Fig. 02Fine mesh volume for PCM cooling geometry
07

Outcome

An early-stage thermal subsystem page showing CAD geometry, mesh visuals, PCM material photos, prototype images, and packaging constraints.

Supports mechanical design through thermal reasoning, CAD, simulation-style outputs, material packaging, manufacturability, and user-centred constraints.

08

Next Steps

  • Thermal product concepts need clear material across geometry, material behaviour, packaging, and user context.
  • Privacy-safe project pages can communicate engineering judgement without publishing sensitive reports.
  • Add concise annotations around the mesh, PCM material choice, enclosure geometry, and comfort constraints if reviewed notes are available.
  • Use only redacted or privacy-reviewed documentation if a public report link is added later.