A helmet manufacturing method involves: producing a shell and a protector, the shell having two opposing cheek-protecting portions, the protector having a jaw-protecting portion and a neck-protecting portion connected to the jaw-protecting portion; putting the shell and the protector in a die such that bottom edges of the cheek-protecting portions of the shell connect to a top edge of the neck-protecting portion of the protector; introducing a foam material into the die, apply heat and pressure to the foam material such that the foam material expands and binds to an inner side of the shell and an inner side of the protector; and taking a helmet finished product out of the die. Therefore, both the jaw-protecting portion of the integrally-formed protector and the helmet finished product are reinforced.

A helmet manufacturing method involves: producing a shell and a protector, the shell having two opposing cheek-protecting portions, the protector having a jaw-protecting portion and a neck-protecting portion connected to the jaw-protecting portion; putting the shell and the protector in a die such that bottom edges of the cheek-protecting portions of the shell connect to a top edge of the neck-protecting portion of the protector; introducing a foam material into the die, apply heat and pressure to the foam material such that the foam material expands and binds to an inner side of the shell and an inner side of the protector; and taking a helmet finished product out of the die. Therefore, both the jaw-protecting portion of the integrally-formed protector and the helmet finished product are reinforced.

A helmet comprising a first protective layer, the first protective layer comprising at least one accessory mount portion for receiving an accessory mount or an accessory, the at least one accessory mount portion being arranged integrally as a part of the first protective layer and configured to disintegrate from the rest of the first protective layer in response to a mechanical impact to the at least one accessory mount portion for preventing the accessory mount portion and/or the accessory from penetrating through the helmet.

A helmet comprising a first protective layer, the first protective layer comprising at least one accessory mount portion for receiving an accessory mount or an accessory, the at least one accessory mount portion being arranged integrally as a part of the first protective layer and configured to disintegrate from the rest of the first protective layer in response to a mechanical impact to the at least one accessory mount portion for preventing the accessory mount portion and/or the accessory from penetrating through the helmet.

Custom manufactured headwear for a subject's head is provided. The headwear comprises an inner layer deposited by an additive manufacturing device. The headwear further comprises 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 determining the shape of the headwear.

A safety helmet includes an outer shell configured for surrounding a head of a user, and an infrared reflective layer disposed in an interior of the outer shell. The infrared reflective layer is configured for reflecting at a least a portion of incident infrared radiation transmitted through the outer shell. The infrared reflective layer has infrared reflectivity of at least 40%. The safety helmet further may have an evaporative cooling pad positioned within a cavity defined by the inner surface of the outer shell. A method of manufacturing a safety helmet is also disclosed.

A safety helmet includes an outer shell configured for surrounding a head of a user, and an infrared reflective layer disposed in an interior of the outer shell. The infrared reflective layer is configured for reflecting at a least a portion of incident infrared radiation transmitted through the outer shell. The infrared reflective layer has infrared reflectivity of at least 40%. The safety helmet further may have an evaporative cooling pad positioned within a cavity defined by the inner surface of the outer shell. A method of manufacturing a safety helmet is also disclosed.

A custom-fitted protective sports equipment 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 safety standard. At a second location different from the first location, the custom-fitted protective sports equipment is 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.

Disclosed are devices and methods for optimizing a protective helmet or other item of protective clothing with one or more enhanced principal impact zones and/or impact elements that incorporate protective features that can be particularized to a specific player-position and/or the individual behavior of a specific player or wearer.

Disclosed are devices and methods for optimizing a protective helmet or other item of protective clothing with one or more enhanced principal impact zones and/or impact elements that incorporate protective features that can be particularized to a specific player-position and/or the individual behavior of a specific player or wearer.