Expanded Polystyrene (EPS) is commonly used as an inner liner for a bicycle helmet due to its outstanding energy absorption characteristic and light-weight property. The current investigation presents a novel technique to manufacture hybrid EPS/honeycomb structure foam using an integrated manufacturing approach to further enhance the energy dissipation properties for improved safety against head injuries. Different foam designs were analysed under curb-stone impact tests and the failure mechanisms are deliberated. Integrated EPS-honeycomb hybrid liners have shown up to 20% higher energy absorption, with the additional energy being absorbed in associated densification of foam and the elastic buckling features of the honeycomb.
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