June 10, 2025

For their spring capstone project, five mechanical engineers created a new helmet fit with environmental sensors to improve work zone safety.

A student’s Mizzou Engineering experience isn’t complete without a hands-on capstone project. These group projects encourage mechanical engineering students to solve problems they’re interested in and give them free reign to design an innovative solution they think the world needs.

This semester, one group of students integrated sensors with real-time monitoring capabilities of physical conditions into construction helmets to improve work zone safety.

“We wanted to meet the growing demand for smart personal protective equipment (PPE) in industries that prioritize safety and efficiency,” the team said.

To this end, they incorporated a suite of sensors, including air quality sensors to detect harmful gases and particulates, temperature and humidity sensors to monitor working conditions, a microphone to measure noise levels, and an accelerometer to detect impacts or falls. The helmet then transmits that data to a dashboard that workers and site managers can monitor to ensure safety.

The team consisted of students Cayse Martin, Brian Schwartz, Cody Stiern, Tyler Ruhland and Elie Chammas. Learn more about their project and what they learned from the experience.

Project overview

Schwartz: Our team set out to address the lack of a real-time monitoring system for basic environmental and safety conditions on construction sites. Existing commercial devices tend to be overly complex, incorporating cameras and invasive tracking features that contribute to micromanagement rather than supporting workers.

We wanted to design a solution that focused on essential data — such as temperature, humidity, air quality, noise levels and head impact detection — without compromising worker privacy.

Martin: The idea for WorkWise came from my direct experience on construction sites. I have firsthand knowledge of the day-to-day use of safety helmets and identified a gap: Most helmets offer physical protection but do not provide feedback about environmental hazards or potential safety risks.

This inspired the concept of integrating sensors into a helmet to passively monitor real-time conditions and provide valuable feedback without adding extra burden to the worker.

An iterative process

Stiern: Our project began with brainstorming what types of sensors would provide meaningful safety data. We researched various sensor technologies compatible with the Raspberry Pi platform, focusing on air quality, temperature, humidity, sound levels, and accelerometers for knock detection.

The development process included initial prototyping, wiring and integrating each sensor, followed by calibration to ensure accurate readings. Once the hardware setup was complete, we developed a system to wirelessly transmit the sensor data to a web dashboard for real-time access.

After completing the final prototype, we performed functional testing and structural integrity testing to ensure the helmet could withstand real-world conditions.

Chammas: The final prototype of WorkWise successfully collected accurate environmental and safety data in real time and transmitted that data wirelessly to a dedicated web interface. Structural integrity testing confirmed that the embedded sensors and wiring did not compromise the protective capabilities of the helmet.

Overall, the system performed as intended, demonstrating reliability and ease of use in simulated worksite conditions.

The Missouri Method in practice

Stiern: Throughout the development of WorkWise, we learned the importance of balancing functionality with user comfort and safety. We gained hands-on experience in sensor integration, data communication and hardware prototyping. Time management and iterative design were critical. We had to be flexible when components didn’t work as expected and adapt our designs accordingly

We also developed valuable skills in team collaboration, system-level thinking and communicating technical decisions clearly. Perhaps most importantly, we learned how to design with the end user in mind, prioritizing simplicity, effectiveness and usability.

Ruhland: Our coursework at Mizzou, particularly the class “Thermal Fluids Laboratory,” equipped us with a strong foundation in understanding sensor behavior and calibration, which were essential for our project. The collaborative lab work and project-based assignments throughout our degree also helped us develop the practical skills and team communication strategies that were critical for the success of WorkWise.

Learn more about spring 2025 capstones at Mizzou Engineering!