A system for forming a deep drawn helmet and method therefor are disclosed. The system includes a forming draw ring and a non-forming draw ring and supports a prepreg stack between a forming aperture of the forming draw ring and a non-forming aperture of the non-forming draw ring. The system clamps a flange portion of the prepreg stack between a contact surface of the forming draw ring and a contact surface of the non-forming draw ring, which forms a clamped assembly of the rings and the prepreg stack. The system then forms a deep drawn helmet preform from the prepreg stack of the clamped assembly. The same system or a different forming system then consolidates one or more of the preforms into a final deep drawn helmet. The system can control sliding of the flange during forming of the helmet preform without reducing the flange clamping force.

The present invention provides a sawdust helmet and a manufacturing method. The sawdust helmet comprises an outer housing; a buffer body containing sawdust is installed at the inner side of the outer housing; the buffer body is integrally formed, and the size of the buffer body is adapted with the size of the outer housing; a fabric inner cushion body is padded at the inner side of the buffer body; and a helmet belt is fixedly installed at the bottom of the outer housing. The buffer body is composed of a sawdust layer and a foam material layer. The sawdust layer is composed of cork chips or non-cork chips. The buffer body is composed of the sawdust layer and the foam material layer, and the decorative pattern formed by the sawdust can increase the beauty of the helmet.

A custom-fitted helmet and a method of making the same can comprise, at a first location, obtaining head data for a customer's head comprising a length, a width, and at least one head contour. With at least one processor, generating a computerized three-dimensional (3D) headform matching the customer's head length, width, and head contour from the head data. The 3D headform can be compared to a helmet safety standard. At a second location different from the first location, a custom-fitted helmet based on the 3D headform can be formed, wherein the custom-fitted helmet satisfies the safety standard and comprises an inner surface comprising a topography that conforms to the length, width, and at least one contour of the customer's head. The first location can be a home or a store. Obtaining the head data from photographic images of a deformable interface member disposed on the customer's head.

A connector including: first part designed to be connected to crown of protective helmet, second part designed to be connected to crown of protective helmet and fitted in removable manner on first part, connecting part mechanically connecting first part and second part so as to form first mechanical connection, movable part moving between first and second positions and configured: to prevent first and second parts from coming detached from one another when the parts are subjected to first threshold tensile force, when movable part is in first position, to enable first and second parts to be detached from one another when the parts are subjected to second threshold tensile force lower than that of first threshold tensile force, when movable part is in second position. The invention also relates to protective helmet provided with one such connector, as well as to an assembly method of such connector.

A connector including: first part designed to be connected to crown of protective helmet, second part designed to be connected to crown of protective helmet and fitted in removable manner on first part, connecting part mechanically connecting first part and second part so as to form first mechanical connection, movable part moving between first and second positions and configured: to prevent first and second parts from coming detached from one another when the parts are subjected to first threshold tensile force, when movable part is in first position, to enable first and second parts to be detached from one another when the parts are subjected to second threshold tensile force lower than that of first threshold tensile force, when movable part is in second position. The invention also relates to protective helmet provided with one such connector, as well as to an assembly method of such connector.

The present invention provides a head protective gear comprising a plurality of three-dimensional inserts configured into hollow members made of an energy absorbing material, formulations forming the energy absorbing material, method of preparing the energy absorbing material. The present invention is designed to protect against or at least mitigate both linear and angular impacts exerted on a head section of a wearer of the head protective gear incorporated with the hollow three-dimensional structure made of the energy absorbing material.

Custom manufactured headwear for a subject's head includes an inner layer shaped to contact the head of the subject at predetermined areas. The inner layer is deposited by an additive manufacturing device. The headwear further includes an outer layer deposited by the additive manufacturing device. The inner layer and the outer layer are each formed by the additive manufacture device utilizing a device data file derived from a subject data file. The subject data file is representative of the shape of the head and the device data file determines the shape of the headwear.

A method for manufacturing a high performance thermoplastic matrix composite ballistic helmet includes forming/shaping highly consolidated helmet preforms free of wrinkles and with no cuts or seams from a flat stack of 0/90 uni-directional prepreg layers, both with and without carbon epoxy skins or layers, using a pressure forming process. The wrinkle free and no cuts pre-formed helmet shell is pre-heated and placed between match-metal dies in a compression molding press to be molded under constant pressure during heating at high temperature and cooling down to below 160 F. in less than 45 minutes.

A total contact helmet, including a body that is customizable to an individual's head and having force distribution means for distributing the force of an impact to a large surface area of the body. A total contact helmet insert, including a body that is customizable to an individual's head and having force distribution means for distributing the force of an impact to a large surface area of the body, the total contact helmet insert being insertable under an existing helmet or as an inner shell as part of an existing helmet. A method of protecting the head of a user by the user wearing the total contact helmet, and when receiving an outside impacting force to the total contact helmet, distributing the force of impact over the surface area of the total contact helmet.

A method of forming a dual cure three-dimensional object by additive manufacturing may be carried out by mixing a first precursor liquid and a second precursor liquid to produce a polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component (e.g., a second reactive component) that is different from the first component (e.g., that does not contain a cationic photoinitiator, or is further solidified by a different physical mechanism, or further reacted, polymerized or chain extended by a different chemical reaction). In the foregoing: (i) at least one reactant of the second solidifiable component is contained in the first precursor liquid, and (ii) at least one reactant or catalyst of the second solidifiable component is contained in the second precursor liquid. Once mixed, the three-dimensional object may be formed from the resin by a dual cure additive manufacturing process.