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Michigan State University engineers are revolutionizing football communication by helping players overcome stadium noise with innovative helmet inserts.
Michigan State Engineers Innovate for Spartan Football
Michigan State University (MSU) is tackling one of football’s enduring challenges: effectively communicating plays amid the deafening roar of tens of thousands of fans. With the NCAA approving coach-to-player communication for Football Bowl Subdivision (FBS) teams in the 2024 season, MSU’s engineering team stepped in to ensure seamless adoption of this new system.
The effort, led by Tamara Reid Bush, an associate professor of mechanical and biomedical engineering, has resulted in cutting-edge 3D-printed helmet inserts that reduce ambient noise. These devices are critical to making the coach-to-player communication system—already a staple in the NFL—effective for college teams.
“This project really captures the dual purpose of our work: solving real-world problems and inspiring students to innovate,” Bush said.
New NCAA Rules Bring NFL Tech to College Football
The NCAA’s decision to allow one offensive and one defensive player on each team to use coach-to-player communication marks a major shift in game dynamics. The technology relies on a helmet device that transmits play calls directly to designated players. However, without adequate noise reduction, even the most advanced tech can be rendered useless in packed stadiums.
“We wanted our student-athletes to get the call from their coach with minimal interference,” said Andrew Kolpacki, MSU’s head football equipment manager.
Bush and her team at the Biomechanical Design Research Lab worked on a solution: custom 3D-printed inserts tailored to different helmet brands and sizes. These inserts snap securely into the earholes of helmets, muffling background noise while ensuring the devices stay in place during hard tackles.
Engineering a Perfect Fit for Football Helmets
Rylie DuBois, a second-year biosystems engineering student, led the design process. Using computer-aided drafting (CAD), she created prototypes that underwent multiple iterations based on player feedback.
“A little bit of pressure won’t knock them out,” DuBois explained. “We designed them to remain in place even after heavy hits.”
The task was far from straightforward. Different helmet manufacturers have varying earhole sizes and shapes, requiring the team to meticulously adjust each design. The inserts had to strike a delicate balance: snug enough to stay put without protruding or catching on external forces.
A Game-Day Success Story for MSU Engineers
For both Bush and DuBois, seeing their work on the field was a defining moment. The inserts debuted during MSU’s 2024 football season, with quarterback Aidan Chiles sporting the new tech. The inserts’ success brought a sense of accomplishment to the engineering team.
“When I saw them on the jumbotron, I couldn’t contain my excitement,” DuBois said. “I told everyone, ‘I designed those!’”
Bush echoed the sentiment, sharing the pride of seeing her students’ work directly impact the game.
Broader Implications for Biomechanical Engineering
The success of MSU’s helmet insert project highlights the potential for collaboration between engineering and athletics. It also underscores how educational institutions can provide students with hands-on experience that translates to real-world applications.
DuBois said the project enhanced her skills in project management, technical design, and problem-solving, all while addressing a critical biomechanical challenge. “This experience has made me more confident in my engineering abilities,” she said.
As more college teams adopt the coach-to-player communication system, MSU’s innovative approach could set a standard for how engineering can support athletic performance.
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