Welding Helmet Back Extension with Ventilation System

Design by: CubeCtrl
Concept by: Marikina Polytechnic College Students
Manufacturing Method: FDM 3D Printing

Design

A custom rear extension module for a welding helmet designed to enhance user comfort and airflow management. The structure integrates a compact fan enclosure, air filtration housing, and directional airflow channels while maintaining a form that complements the existing helmet geometry.

The design features a smooth aerodynamic shell that blends with the helmet's curvature while protecting the internal ventilation components. Air intake vents are positioned at the upper rear section to draw in filtered air, while a forward-facing nozzle channels airflow toward the user's face area.

Material

PETG (Polyethylene Terephthalate Glycol)

Chosen for:

• High impact resistance

• Good heat tolerance for workshop environments

• Durability under repeated use

• Chemical resistance against common shop contaminants

• Suitable for functional FDM 3D printed components

Function

• Integrated Fan Enclosure
  Housing for a compact ventilation fan to actively move air through the system.

• Air Filtration Chamber
  Dedicated space for an air filter to reduce dust, smoke particles, and contaminants.

• Rear Air Intake Vents
  Multiple intake openings positioned at the top of the unit to maximize airflow capture.

• Directed Airflow Nozzle
  Extended front outlet that guides fresh air toward the user's breathing zone.

• Ergonomic Helmet Extension
  Rear housing extends the helmet structure without interfering with mobility or balance.

• Modular Assembly Design
  Designed for easy installation and potential maintenance of internal components.

Application

• Welding workshops

• Industrial fabrication environments

• Metalworking facilities

• DIY welding setups

• Safety equipment prototyping and customization

Project Description

This project supports the thesis of Raymond, Jeza Kate Princess, and Jean from Marikina Polytechnic College, titled “SMAW Fume Detection using Image Processing Model for Innovative Welding Helmet.”

A custom welding helmet back extension was designed to house ventilation components that improve airflow and help support the integration of the system’s detection hardware. The design includes air intake vents, a filtration chamber, and a directed airflow outlet toward the welder’s breathing area.

The prototype was designed by CubeCtrl and fabricated using PETG through FDM 3D printing for durability and functional testing.