Bryn Heinemann

All projects

SafeBase.AI: Helmet-Mounted Sensor Housing

Mechanical design, Ironsite Construction Innovation Challenge. Spring 2026.

Sole mechanical designer on a team that placed third and won $10,000. Built a helmet-mounted enclosure for a heat-exposure monitoring prototype in about two weeks.

ToolsSolidWorks, Ender 3 (FFF), PLA, Assembly drawings

Printed housing with the SafeBase.AI lid, assembled.
Printed housing with the SafeBase.AI lid, assembled.

Design

A two-part housing, 2.95 × 1.88 × 1.04 in, slides onto the rear of the helmet. It holds an ESP32, a 2000 mAh battery, and the sensor boards; I test-fit it against the real electronics. An SHT40 temperature and humidity sensor sits in a removable vented tab, and an IR sensor on the front helmet liner is aimed at the wearer.

Exploded view

Exploded-view animation of the housing: lid, sensor boards, ESP32, battery, and main housing.

Assembly

Assembly drawing with exploded view and parts list.
Assembly drawing with exploded view and parts list.
Housing mounted on the hard hat.
Housing mounted on the hard hat.

3D model

Main housing, preview render of the 3D model
Housing parts from my SolidWorks files, exported for the web.