Traumatic Brain Injury (TBI) is a global health crisis, with concussions — classified as mild TBI — being particularly common in sports and daily activities. These non-penetrative injuries complicate diagnosis and analysis due to ethical and observational challenges. This thesis aims to develop a biofidelic head model for lab-based impact testing, bridging the gap of anatomical representation between computational models and physical validation.

This research focuses on characterizing materials that mimic the mechanical properties of human brain and skull tissues under impact conditions. These materials are tested for their ability to simulate the brain’s compressive and shear responses and the skull’s flexural strength, using advanced manufacturing techniques. The research, structured across five chapters, reviews existing head impact methods and current practices for simulant characterization, selects and tests brain and skull simulants, and designs a comprehensive methodology for creating a full-scale biofidelic head model, proposing advancements for more accurate TBI analysis and prevention.