Students Develop Groundbreaking “Mechanical Brain” to Advance Crash Safety Research

A team of engineering students at North Central State College is pushing the boundaries of crash safety research with a first-of-its-kind project: a 3D-printed “mechanical brain” designed to mimic how the human brain responds during a crash.

The innovative work led by Bachelor of Science in Mechanical Engineering Technology (BASMET) students Jakob Fishel, Mark Depinet, Aiden Payne, and Kevin Romero has evolved over several years into a system that could one day help predict and prevent traumatic brain injuries in car accidents and even contact sports.

“This is creating a first-of-its-kind surrogate brain inside a 3D-printed skull,” Jakob explained.  “The goal is to eventually link it to a measurement system that can help predict injuries.”

The project builds on earlier student research that used simplified materials to simulate a brain.  Over time, the design has grown more complex and more realistic.

“The BASMET class before us was simulating a sheep brain,” Mark said. “It kind of evolved from that.”

Today’s version features a brain made from thermoplastic polyurethane (TPU), a flexible 3D-printed material that better mimics the properties of real brain tissue.  The model includes detailed structural features, such as ridges that allow researchers to track movement using ultrasound technology.

“It’s easier to see on the ultrasound machine,” Aiden said. “The different elevations make it easier to track how the brain moves.”

The brain sits inside a carefully engineered 3D-printed skull, which has gone through multiple design iterations.  Earlier versions were bulky and difficult to assemble, but the current design simplifies the process while maintaining accuracy.

“We went from a three-piece assembly to a two-piece design,” Aiden said. “It’s more efficient and easier to work with, even though it’s still a tight fit.”

The project has gained valuable support from industry and research partners.  The team collaborated with Humanetics, a leading manufacturer of anthropomorphic test devices (also commonly known as crash test dummies) based in nearby Huron, Ohio, which provided mentorship, resources, and 3D printing assistance.

“They helped mentor us through the initial phases,” Mark said. “Having the real-world experience and input made a huge difference.”

The students also worked closely with researchers at the Vehicle Research and Test Center (VRTC), part of the National Highway Traffic Safety Administration (NHTSA). VRTC experts provided guidance on design improvements and testing methods, including the use of ultrasound tracking.

“They helped us correlate our data with human testing data,” Mark said. “They also suggested features like the brain ridges to improve measurement accuracy.”

Testing took place at The Ohio State University’s biomechanical lab, where the device was subjected to rotational forces like those experienced in car crashes.  Sensors captured how the brain model moved inside the skull during impact. “The best way to think about it is like your head jerking forward in a car crash,” Aiden explained.

According to preliminary observations, the mechanical brain’s movement closely matches that of human brain specimens in similar tests, which is an encouraging sign for the project’s future.

Instructor Mike Beebe said the project marks a significant milestone. “This team has been the first to create a mechanical brain in a crash test dummy head that reacts like a human brain in rotational testing,” Beebe said.  “It has the potential to measure brain injury in the future.” Ultimately, the students hope their work will contribute to safer vehicle design and improved protective equipment.

“The final goal is to use this in real-world applications,” Jakob said. “Whether it’s making cars safer or improving helmets in sports like football, we want to reduce concussions and save lives.”

Beyond the technical achievements, the project provided valuable hands-on experience with the students involved. “My biggest takeaway is learning how to work as a team,” Aiden said. “We had to figure out each step together and make sure everything came together.” The project is also opening doors for future opportunities.  Jakob plans to pursue a master’s degree in biomechanics at The Ohio State University and hopes to continue developing the research. “I’d love to take this project further,” he said.

Meanwhile, other team members are preparing to enter the workforce, bringing them real-world engineering experience shaped by the project. With a strong foundation now in place, the team hopes future students will continue refining the technology.  “We’ve built something that others can take and run with,” Aiden said. “There’s a lot more potential here.”

As research continues, this student-driven innovation could play a key role in better understanding brain injuries, and ultimately in helping prevent them.