Design, Fabrication and Preliminary Performance Evaluation of a Locally Manufactured Personal Flotation Device for Calm-Water Applications

Abstract

This study presents the design, fabrication, and preliminary experimental evaluation of a locally manufactured vest-type Personal Flotation Device (PFD) for adults weighing 75–80 kg under controlled calm-water conditions. The prototype used locally available closed-cell polyethylene foam, polyester fabric, nylon webbing, plastic buckles, mesh fabric, and reinforced stitching. It measured 0.63 m × 0.59 m × 0.06 m. Analytical calculations yielded a bounding volume of 0.0223 m³ and an upper-bound buoyancy estimate of 218.76 N. A simplified stability analysis estimated a metacentric height of 0.40 m, while the fastening system had a calculated design load of approximately 2,280 N. These values were treated as design estimates rather than measured performance or strength. Experimental evaluation involved 10 adult participants at Alova Hotel Swimming Pool, Minna, Nigeria. All participants maintained flotation for 15 min, with head clearance of 9–11 cm and a mean of 10.2 cm. Mean ratings were 4.60 ± 0.52/5 for buoyancy, 4.40 ± 0.52/5 for stability, and 4.30 ± 0.48/5 for comfort. Following a controlled 90° rotational disturbance, participants could assist recovery using normal arm and body movements; mean recovery time was 2.95 ± 0.16 s. PFD mass increased from 1.85 to 1.92 kg after immersion and draining, representing a 3.78% increase. No visible damage affecting fastening or flotation function was observed. The findings indicate preliminary feasibility for calm-water applications but do not establish certification, standards compliance, or structural strength. Further research should include direct buoyancy measurement, tensile testing, replicated trials, participant-level data, and broader environmental testing.