Development of THOR-FLx: A Biofidelic Lower Extremity for Use with 5th Percentile Female Crash Test Dummies

A new lower leg/ankle/foot system has been designed and fabricated to assess the potential for lower limb injuries to small females in the automotive crash environment. The new lower extremity can be retrofitted at present to the distal femur of the 5th percentile female Hybrid III dummy. Future plans are for integration of this design into the 5th percentile female THOR dummy now under development. The anthropometry of the lower leg and foot is based mainly on data developed by Robbins for the 5th percentile female, while the biomechanical response requirements are based upon scaling of 50th percentile male THOR-Lx responses. The design consists of the knee, tibia, ankle joints, foot, a representation of the Achilles tendon, and associated flesh/skins. The new lower extremity, known as THOR-FLx, is designed to be biofidelic under dynamic axial loading of the tibia, static and dynamic dorsiflexion, static plantarflexion and inversion/eversion. Instrumentation includes accelerometers, load cells, and rotary potentiometers to capture relevant kinematic and dynamic information from the foot and tibia. This paper will describe the performance requirements for THOR-FLx, the methodology used in its' development, results of component tests, and the biofidelity tests conducted on the full assembly.