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.

Disclosed are s full-form flat-knitted helmet shell preform, the preparation method, and the helmet shell, which belong to the field of helmet material technology. Two different knitting directions of the helmet shell preforms are prepared by means of longitudinal knitting and transverse knitting combined with partial knitting respectively; Meanwhile, reinforced yarn is added during the knitting process of the preforms to obtain the transversely and longitudinally knitted helmet shell preforms with reinforced yarn. The fabric structure of the preforms disclosed in this invention is a flat-knitted three-dimensional fabric with reinforced yarns, which solves the problem of low tensile strength and high elongation of flat-knitted fabrics, and solves the poor impact resistance caused by poor bonding strength between layers of helmet shells to some extent. Moreover, the method of preparing helmet shells from preforms improves production efficiency, reduces material waste, and solves the problem of poor dimensional stability.

Disclosed are s full-form flat-knitted helmet shell preform, the preparation method, and the helmet shell, which belong to the field of helmet material technology. Two different knitting directions of the helmet shell preforms are prepared by means of longitudinal knitting and transverse knitting combined with partial knitting respectively; Meanwhile, reinforced yarn is added during the knitting process of the preforms to obtain the transversely and longitudinally knitted helmet shell preforms with reinforced yarn. The fabric structure of the preforms disclosed in this invention is a flat-knitted three-dimensional fabric with reinforced yarns, which solves the problem of low tensile strength and high elongation of flat-knitted fabrics, and solves the poor impact resistance caused by poor bonding strength between layers of helmet shells to some extent. Moreover, the method of preparing helmet shells from preforms improves production efficiency, reduces material waste, and solves the problem of poor dimensional stability.

Body protection devices, particularly protective helmets are provided, which comprise a shell of plastic material or of fiber-reinforced plastic material, wherein the shell comprises an outer coating layer formed of a polyacrylic or polyepoxide polymeric matrix including graphene fillers. Processes for the production of protection devices are also provided.

Body protection devices, particularly protective helmets are provided, which comprise a shell of plastic material or of fiber-reinforced plastic material, wherein the shell comprises an outer coating layer formed of a polyacrylic or polyepoxide polymeric matrix including graphene fillers. Processes for the production of protection devices are also provided.

The present disclosure is for a luminous helmet, comprising an outer shell configured to fit over a human head, an inner shell, a light-emitting band arranged along an elongated slit opening on the outer shell, and a light transmitting groove enclosing the light emitting band. In the manufacturing process, the outer shell was formed first, with a slit cut to match the light transmitting groove. The light-transmitting groove, comprising fixing grooves, engage fixing strips extending from edges of the outer shell along the slit opening. This structure then serves as a base to house the light-emitting band, and to receive pressure injection of the inner shell material.

There is provided a helmet engageable with a human head portion. The helmet includes an inner shell, an outer shell and a shock absorbing layer. The shock absorbing layer is located between the inner shell and the outer shell, include at least one 3D structure and is defined by a plurality of interconnected 5 surfaces with a plurality of openings defined inbetween. A designing process is provided, including steps of providing a virtual inner shell model and outer shell model of the virtual helmet model, positioning virtual curves on the virtual inner shell/outer shell model, and generating virtual minimal surfaces. A manufacturing process is 10 further provided, including steps of conceiving the virtual helmet model using at least some steps of the designing process and additive manufacturing at least a portion of the helmet.

A method and apparatus to attach an Electroluminescent wire and power inverter to a helmet is disclosed. Dabs of hot glue are injected at various locations to form a pattern on a helmet top surface. Segments of heat shrink tubing are inserted into the injected hot glue on the surface to permit the heat shrink tubing segments to shrink and adhere to the helmet. Electroluminescent wire is inserted into the partially shrunk segments of heat shrink tubing. A power inverter is attached to the helmet and connected to the electroluminescent wire to create a light pattern.

A garment worn by a wearer has an exterior shell and an interior shell with various impact absorbing material between the exterior shell and the interior shell. The impact absorbing material includes multiple structures, such as rods or filaments, capable of deforming when force is applied then returning to its state prior to application of the force. In various embodiments, the impact absorbing material is manufactured using injection molding to allow positioning of various structures in the impact absorbing material relative to each other during manufacture. During manufacturing, one or more living hinges are included in portions of the impact absorbing material to allow certain portions of the impact absorbing material to be accurately positioned relative to each other. Other manufacturing methods may be used, such as three-dimensional printing may be used to include structures in the impact absorbing material.

A garment worn by a wearer has an exterior shell and an interior shell with various impact absorbing material between the exterior shell and the interior shell. The impact absorbing material includes multiple structures, such as rods or filaments, capable of deforming when force is applied then returning to its state prior to application of the force. In various embodiments, the impact absorbing material is manufactured using injection molding to allow positioning of various structures in the impact absorbing material relative to each other during manufacture. During manufacturing, one or more living hinges are included in portions of the impact absorbing material to allow certain portions of the impact absorbing material to be accurately positioned relative to each other. Other manufacturing methods may be used, such as three-dimensional printing may be used to include structures in the impact absorbing material.