The invention relates to a protective sports helmet purposely designed for a selected group of helmet wearers from amongst a larger population of helmet wearers. A multi-step method for helmet design starts by collecting information from a population of players that may include information about the shape of a player's head and the impacts the player has sustained. This information is then processed to create player population information that is sorted to create categories. Advanced mathematical techniques are utilized to further sort these categories into player groups or data sets based on player attributes. Once the player groups are identified, another multi-step process is utilized to design optimized helmet prototype models for each player group. These optimized helmet prototype models are then further processed into complete helmet models by determining a structural design and chemical composition that is manufacturable and has mechanical properties that are substantially similar to the optimized helmet prototype model. Physical helmet prototypes are then created and tested using a unique helmet standard derived from information associated with each player group. Once the prototypes pass testing, the complete helmet models can be manufactured to create actual stock helmets or stock helmet components for future players whose characteristics and attributes place them within the selected player group.

The invention relates to a protective sports helmet purposely designed for a selected group of helmet wearers from amongst a larger population of helmet wearers. A multi-step method for helmet design starts by collecting information from a population of players that may include information about the shape of a player's head and the impacts the player has sustained. This information is then processed to create player population information that is sorted to create categories. Advanced mathematical techniques are utilized to further sort these categories into player groups or data sets based on player attributes. Once the player groups are identified, another multi-step process is utilized to design optimized helmet prototype models for each player group. These optimized helmet prototype models are then further processed into complete helmet models by determining a structural design and chemical composition that is manufacturable and has mechanical properties that are substantially similar to the optimized helmet prototype model. Physical helmet prototypes are then created and tested using a unique helmet standard derived from information associated with each player group. Once the prototypes pass testing, the complete helmet models can be manufactured to create actual stock helmets or stock helmet components for future players whose characteristics and attributes place them within the selected player group.

A method of producing a custom mask and strap assembly for an aviator's helmet, including: creating a custom mold using additive manufacturing based on at least two physiognomy parameters; forming the custom mask made of an elastomer from the custom mold; assembling the custom mask with a hard shell; and, securing the custom mask and the hard shell to the helmet by a strap assembly, the strap assembly including a strap anchor securable to the helmet and a strap slidably connected to the strap anchor. The strap includes a first side and a second side and further includes a first end securable to a first portion of the mask with the first side facing the mask and a second end securable to a second portion of the mask with the second side facing the mask.

A method for manufacturing a helmet with hidden light source includes: providing a transparent base film and a screen printing plate, wherein the base film comprises a first portion and a second portion, and the screen printing plate covers and corresponds to the first portion; printing a lightproof ink layer on the second portion and the screen printing plate; removing the screen printing plate; coating a light transmitting ink layer on the lightproof ink layer; attaching at least one light source on the light transmitting ink layer corresponding to the first portion; and forming a helmet base to cover the at least one light source.

A method for manufacturing a helmet with hidden light source includes: providing a transparent base film and a screen printing plate, wherein the base film comprises a first portion and a second portion, and the screen printing plate covers and corresponds to the first portion; printing a lightproof ink layer on the second portion and the screen printing plate; removing the screen printing plate; coating a light transmitting ink layer on the lightproof ink layer; attaching at least one light source on the light transmitting ink layer corresponding to the first portion; and forming a helmet base to cover the at least one light source.

A comfort padding, configured to be attached at an innermost surface of a helmet, which is facing a wearer's head, for providing a sliding movement in the comfort padding in response to an oblique force applied to the helmet in use is provided. The comfort padding comprises a layer of membrane material provided closer to the helmet than a layer of stretchable fabric or nonwoven material, and between the two layers there is a layer of open cell polymer foam, the membrane layer has a low friction surface allowing for a sliding movement between the layer of open cell polymer foam and the membrane material. A helmet comprising the comfort padding

A comfort padding, configured to be attached at an innermost surface of a helmet, which is facing a wearer's head, for providing a sliding movement in the comfort padding in response to an oblique force applied to the helmet in use is provided. The comfort padding comprises a layer of membrane material provided closer to the helmet than a layer of stretchable fabric or nonwoven material, and between the two layers there is a layer of open cell polymer foam, the membrane layer has a low friction surface allowing for a sliding movement between the layer of open cell polymer foam and the membrane material. A helmet comprising the comfort padding

Apparatus provides point of service to manufacture a custom cranial remodeling device for correction of cranial deformity of a subject. The apparatus comprises capture apparatus disposed at a physical location for capturing three dimensional digital data of the head of the subject and generating a three-dimensional digital data file representative of the head and an additive manufacture device located at the physical location. The apparatus further comprises a processor that operates to process the three-dimensional digital data file to produce a device file comprising the shape for the custom cranial remodeling device. The processor provides the device file to the additive manufacture device. The said additive manufacture device operates to utilize the device file to manufacture the custom cranial remodeling device at the physical location.

Apparatus is provided for point of service manufacture of custom headwear for a subject. The apparatus comprises capture apparatus disposed at a physical location for capturing three dimensional digital data of the head of the subject and generating a three-dimensional digital data file representative of said head; an additive manufacture device located at the physical location; and a processor. The processor operates to process the three-dimensional digital data file to produce a device file comprising the shape for the custom headwear and to provide the device file to the additive manufacture device. The additive manufacture device operates to utilize the device file to manufacture the custom headwear at the physical location.

Custom manufactured headwear for a subject's head is provided. The headwear comprises 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 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.