Aspects of the present disclosure provide a helmet including customized helmet layers and corresponding methods of construction. In one aspect, a method comprises capturing a 3D image of a head corresponding to the head of an individual, and rendering a 3D headform based on the 3D image. A lining layer is formed, which includes a geometry corresponding to the 3D headform and the inner surface of the shell layer such that an inner surface of the lining layer conforms to the shape of a corresponding portion of the 3D headform. An outer surface of the lining layer further conforms to the shape of a corresponding portion of an inner surface of a shell layer. Another aspect of the method comprises forming a shell layer such that the shell layer includes a geometry corresponding to the shape of a portion of the 3D headform.

The present invention relates to protective helmets. Embodiments of the invention have been primarily developed to provide protective helmets, protective helmet components and methods for manufacturing protective helmets, including protective helmets having an enlargeable bell opening. For example, embodiments are described by reference to two-part helmets having a hinged connection which permits bell opening enlargement to enable insertion or removal of a human head. One embodiment provides a manufacturing method whereby a protective helmet is formed as a single piece, and then cut into shell portions to which interlocking edge members is subsequently applied, thereby to facilitate reconnection of the shells along an interlocking edge.

A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).

A light-emitting helmet is provided. The helmet includes a main body, a number of fixing members, and a number of light-emitting lamp strips. The main body includes a shell and inner layer. The shell includes an outer surface and a number of grooves defining in the outer surface. The fixing members are secured in the inner layer. The lamp strips are detachably mounted in the grooves by the fixing frames respectively. In addition, a light-emitting helmet manufacturing method is also provided.

A method for manufacturing a helmet with hidden light sources includes: fixing a helmet housing with at least one light transmitting portion to a base mold; providing a light source protector and a light source belt, and fixing the light source protector to the light source belt, wherein the light source belt comprises a circuit board and a plurality of light sources mounted on, wherein the light source protector comprises a plurality of accommodating holes corresponding to the light sources one by one, and the light sources each are received in a corresponding accommodating hole and enclosed by the light source protector and the circuit board; aligning the light sources to the light transmitting portion and fixing the light source protector to an inner surface of the helmet housing; and injecting a buffer material into the base mold to form a base.

The disclosure relates to a protective sports headgear device and method for manufacturing a protective sports headgear device. The device may include various padding materials that can reduce the risk of head injury for the wearer. One or more external covering layers can be connected to the padding or can surround and retain the padding. The protective sports headgear device may provide protection for the ears of the wearer as well. Additionally, the protective sports headgear device can be suitable for use in the sports of water polo, wrestling, or other sports.

The disclosure relates to a protective sports headgear device and method for manufacturing a protective sports headgear device. The device may include various padding materials that can reduce the risk of head injury for the wearer. One or more external covering layers can be connected to the padding or can surround and retain the padding. The protective sports headgear device may provide protection for the ears of the wearer as well. Additionally, the protective sports headgear device can be suitable for use in the sports of water polo, wrestling, or other sports.

In a method for adapting a thermally deformable item of clothing to a body part, the item is at least partially heated and brought into contact with an abutment region and the appropriate body part. The item of clothing has a side which, in the use position, is directed towards the body and a side which, in the use position, is directed away from the body. At least one pressure-exerting unit subjects that side of the item of clothing which is directed away from the body, at least in part, to a shaping pressure such that the at least partially heated item of clothing is adapted, at least in part, to the shape of the part of the body. The item of clothing is at least partially cooled by a cooling unit such that it is stabilized in the shape adapted to the part of the body.

A helmet and method for forming a helmet having a multi-density impact liner may include forming a puck comprising an interface surface and at least one side is formed. The interface surface of the puck is placed in direct contact with a receiving surface of a cap located in an impact liner mold. Next, the interface surface of the puck is thermally fused directly to the receiving surface of the cap while contemporaneously an impact liner body is formed inside the mold. The impact liner body is fused to the at least one side of the puck, and to a majority of the receiving surface of the cap. The density of the puck may be greater than the density of the impact liner body. The puck and the impact liner body may be EPS, and the cap may be PC.

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.