Design and production of composite bicycle helmet using denim wastes

In addition to the waste generated after the use of textile products, determining how to utilise the waste generated during their production is an important issue in terms of sustainability. This work, carried out with a sustainable approach, aims to produce composite bicycle helmets by reusing denim waste. Different design alternatives have been studied, taking into account safety, ergonomics and user comfort. Based on the selected designs, moulds were made and pieces of denim fabric were placed into these moulds using the hand lay-up method. After the composite material was placed in the moulds, it was shaped under appropriate temperature and pressure. The reuse of waste denim fabrics without the need for recycling processes and their utilisation in a value-added product category such as bicycle helmets reveals both the economic and ecological aspects of the thesis study. The study presents an exemplary practice in sustainable design and production. Since this research is based on helmet design and production, it shows the originality of the study in which an original product design is made depending on the source of the subject. The study details the design phase, the mould-making phase and the production processes. Keywords: sustainability, design, cyclist helmet, composite, denim