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.

Impact-dissipating liners, helmets having an impact-dissipating liner, and methods of fabricating impact-dissipating liners are provided. The liners include a fluid impermeable enclosure having cavities with sidewalls and a fluid contained in the enclosure. The enclosure may have a central portion and lobes extending from the central portion, wherein the central portion and the lobes are adapted to conform to the shape of an internal surface of a helmet. The helmets may include bodies positioned within the cavities of the liner, where, under impact loading, contact between the bodies and the liner absorbs at least some of the energy of the impact loading. Aspects of the invention are particularly adapted for use for head protection, such as, helmets; however, aspects of the invention are also adaptable to provide impact-dissipation for any body or surface that would benefit from such protection.

Software for designing, configuring, and manufacturing a smart, biomechanically aware helmet is described. The software has numerous modules. One module creates instructions on designing and configuring a baseline helmet where number of shell layers, air vents, sensors, lining layer, and other features are provided. Another module is used for creating instructions on the number of energy and impact transformer layers and the mechanical and non-mechanical means used in each to absorb energy from mechanical impacts to the helmet. These dampers can include ball bearings, elastic devices, conical structures, liquids, gels, foams, and other structures that function in the transformer layers which are between the hard shell layers.

A helmet that includes an outer shell having at least a first outer magnetic member, an inner shell having at least a first inner magnetic member, and padding secured inside the inner shell. The first inner magnetic member is spaced from and opposed to the first outer magnetic member, such that the first inner magnetic member repels the first outer magnetic member. The outer shell is connected to the inner shell.

A helmet that includes an outer shell having at least a first outer magnetic member, an inner shell having at least a first inner magnetic member, and padding secured inside the inner shell. The first inner magnetic member is spaced from and opposed to the first outer magnetic member, such that the first inner magnetic member repels the first outer magnetic member. The outer shell is connected to the inner shell.

Disclosed are apparatuses and methods for improving the impact performance of helmets. The disclosed apparatuses and methods allow the head to move within the helmet but dissipate forces upon the head in a plurality of directions using compressible impact-dissipating elements. The compressible impact-dissipating elements are disposed on a base between the head and an outer shell of the helmet. The compressible impact-dissipating elements are attached to the base that is configured to adapt to the interior size/shape of the helmet with which they are used. The compressible impact-dissipating elements are compressible preferably at least 50% of their short-axis dimension, and are also preferably capable of movement in a plurality of directions by the use of appropriate attachment elements allowing for such movement.

Disclosed are apparatuses and methods for improving the impact performance of helmets. The disclosed apparatuses and methods allow the head to move within the helmet but dissipate forces upon the head in a plurality of directions using compressible impact-dissipating elements. The compressible impact-dissipating elements are disposed on a base between the head and an outer shell of the helmet. The compressible impact-dissipating elements are attached to the base that is configured to adapt to the interior size/shape of the helmet with which they are used. The compressible impact-dissipating elements are compressible preferably at least 50% of their short-axis dimension, and are also preferably capable of movement in a plurality of directions by the use of appropriate attachment elements allowing for such movement.

A helmet includes a shell having an interior surface, a padding disposed along the interior surface of the shell, and a chinbar. The padding defines a first engagement surface positioned at a first lateral side of the padding and a second engagement surface positioned at an opposing second lateral side of the padding. The chinbar includes a cage, a first flange, and a second flange. The cage includes a first end defining a third engagement surface and a second end defining a fourth engagement surface. The third engagement surface interfaces with the first engagement surface and the fourth engagement surface interfaces with the second engagement surface. The first flange extends from the first end of the cage. The second flange extends from the second end of the cage. The first flange and the second flange of the chinbar are embedded within the padding.

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.