Head assembly with facial insert for crash test dummy

1. A head assembly for a crash test dummy comprising:

a skull having a recess;

a head skin disposed over said skull;

a facial insert received in said recess and disposed between said skull and said head skin with said facial insert having a plurality of defined cell structures extending entirely through said facial insert between a front surface and an opposing rear surface to define a plurality of walls between said defined cell structures to achieve a repeatable biomechanical response for at least five impact tests that provides for evaluation of potential head injuries during vehicle crash testing; and

at least one sensor disposed within said recess between said skull and said facial insert with said rear surface of said facial insert engaging said at least one sensor to measure a force applied to said facial insert for evaluation during vehicle crash testing.

2. A head assembly as set forth in claim 1 wherein said cell structures are hexagonal in shape.

3. A head assembly as set forth in claim 1 wherein said cell structures are pentagonal in shape.

4. A head assembly as set forth in claim 1 wherein said cell structures are round shape, square shape, or a combination of the round and square shapes.

5. A head assembly as set forth in claim 1 wherein said cell structures are of different sizes or a combination of different sizes.

6. A head assembly as set forth in claim 1 wherein said cell structures include at least a plurality of first cells each having a first cross-sectional area and a plurality of second cells different from said first cells and each having a second cross-sectional area.

7. A head assembly as set forth in claim 6 wherein said first cross-sectional area is greater than said second cross-sectional area.

8. A head assembly as set forth in claim 1 wherein said head skin is disposed on an exterior surface of said skull and said facial insert.

9. A head assembly as set forth in claim 8 wherein said head skin comprises a polymeric material.

10. A head assembly as set forth in claim 1 wherein said skull comprises a metal material.

11. A crash test dummy as set forth in claim 1 , wherein said plurality of walls comprise a plurality of first walls and a plurality of second walls, wherein a wall thickness of said plurality of first walls is different than a wall thickness of said plurality of second walls.

12. A head assembly for a crash test dummy comprising:

a skull having a recess;

a head skin comprising a polymeric material and disposed over said skull;

a facial insert disposed within said recess between said skull and said head skin with said facial insert having a plurality of defined cell structures extending entirely through said facial insert between a front surface and an opposing rear surface to define a plurality of walls between said defined cell structures;

said plurality of defined cell structures having a shape selected from at least one of a hexagonal, pentagonal, round, and square shape to achieve a repeatable biomechanical response for at least five impact tests that provides for evaluation of potential head injuries during vehicle crash testing; and

at least one sensor disposed within said recess between said skull and said facial insert with said rear surface of said facial insert engaging said at least one sensor to measure a force applied to said facial insert for evaluation during vehicle crash testing.

13. A crash test dummy comprising:

a head assembly;

a body operatively attached to said head assembly; and

said head assembly including a skull having a recess, a head skin disposed over said skull, a facial insert disposed within said recess between said skull and said head skin, and at least one sensor disposed within said recess between said skull and said facial insert with said facial insert engaging said at least one sensor to measure a force applied to said facial insert for evaluation during vehicle crash testing, said facial insert having a plurality of defined cell structures extending entirely through said facial insert between a front surface and an opposing rear surface to define a plurality of walls between said defined cell structures that provides for evaluation of potential head injuries during vehicle crash testing to achieve a repeatable biomechanical response for at least five impact tests that provides for evaluation of potential head injuries during vehicle crash testing,

wherein said rear surface is configured for engagement with said at least one sensor.

14. A crash test dummy as set forth in claim 13 wherein said cell structures are hexagonal in shape.

15. A crash test dummy as set forth in claim 13 wherein said cell structures include at least a plurality of first cells each having a first cross-sectional area and a plurality of second cells different from said first cells and each having a second cross-sectional area.

16. A crash test dummy as set forth in claim 15 wherein said first cross-sectional area is greater than said second cross-sectional area.