Two Liberty High School graduates have turned a senior-year class project into a patented invention that could transform baseball helmet safety.
Sid Tekumalla and Joseph Barlow received a U.S. patent for a honeycomb structure that fits inside baseball helmets and recovers at least 90% of its shape after impact. The innovation allows helmets to be safely reused, addressing a persistent problem in the sport where helmets are typically discarded after a significant hit because the padding cannot maintain protective strength.
The structure uses specially engineered Nylon 6 and Nylon 12 materials and could change equipment standards across youth, collegiate and professional baseball levels.
The invention originated in Liberty High School’s Project Lead The Way capstone engineering course, a four-course engineering pathway taught by Kristin Stuby. The students’ classroom testing later proved valid through industry-standard evaluation.
“Sid and Joseph are highly motivated young men who persevered through the patent process to obtain a patent on their PLTW capstone engineering project,” Stuby said. “What excites me most is that the small-scale testing they conducted in a high school setting was later confirmed through large-scale, industry-standard testing.”
Tekumalla is now a junior at Penn State University double majoring in computer science and data science.
Barlow will be graduating in May with degrees in aeronautical science, aviation safety and air traffic control from the Florida Institute of Technology,
Two mentors guided the students through the patent process. Frank Schweighardt advised on material selection, arranged formal testing and provided technical guidance. Jim McDaniel, a patent attorney and colleague of Schweighardt, donated legal services to help file and secure the patent.
Maureen Leeson, assistant superintendent of the Bethlehem Area School District, said the achievement demonstrates the district’s commitment to providing students real-world learning opportunities.
“It’s remarkable that their high school engineering coursework resulted in a U.S. patent, showcasing the real-world opportunities BASD provides,” Leeson said. “This milestone shows what is possible when education, mentorship and student passion intersect.”
Both inventors plan to pursue the sale or licensing of the patent as they continue their careers.
Generative AI was used to draft this story, based on information provided by the Bethlehem Area School District. It was reviewed and edited by lehighvalleylive.com staff.