Articles and methods for obtaining measurements for the design and/or manufacture of personalized and/or customized clothing, and/or alteration of existing patterns or clothing, and for measuring and/or monitoring one or more parameters, such as size(s), shape(s) and dimension(s), of one or more aspects of a body of the wearer of the article. The articles include a stretchable material interwoven with sensors and/or conductive fibers. The articles include socks, bodysuits, bras, gloves, hats, and so forth. The personalized and/or custom-fitted clothing includes shirts, suits, pants, shorts, dresses, skirts, bras and other undergarments, sleepwear, socks, shoes, gloves, hats, exercise/active wear, protective wear (e.g., helmet, shoulder pads, body armor, etc.), and so forth. The articles and methods may further be used for health and fitness assessment.

A method and apparatus for reducing the severity of blows delivered to protective headgear hard outer shells. The method consists of applying cushions to the hard outer shell, forcing the cushions to conform to the contour of the hard outer shell by laying straps over the cushions, applying tension to the straps, and holding the cushions in place by anchoring the straps at the front and rear of the hard outer shell. The apparatus consists of rectangular-shaped cushions, straps that lay atop the cushions, and a rear anchor strap whose ends attach on opposites sides of the front of the hard outer shell, and whose middle extends backward to provide anchor points for other straps in the system. A crown cushion runs over the crown of the hard outer shell and a side cushion wraps around the side of the hard outer shell with overlapping ends that anchor to themselves.

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).

An integrally formed safety helmet structure includes an assembly of a helmet shell or a shell body, a foam filling body enclosed in the shell body and a structure body. Geometrical array texture structures are disposed at the assembling interfaces between the shell body, the structure body and the foam filling body. In manufacturing, by means of a mold or molding module and solid foaming technique, the foam filling body is integrally formed to bond with the shell body and the structure body and the geometrical array texture structures so as to form a compact and rigid multilayer complex reinforcement structure. The complex reinforcement structure not only can enhance the structural strength of the entire safety helmet, but also has the advantages of material-saving, lightweight, high security and easy manufacturing.

A helmet has a memory foam member and an impact dissipating member in moulded together. A process for forming such a helmet is also provided. A helmet has a memory foam member and an impact-dissipating member. The memory foam member is formed from a memory foam material and the impact-dissipating member is formed from an impact-dissipating material and has an impact-dissipating member inner side and an impact-dissipating member outer side opposite the impact-dissipating member inner side. The memory foam member is in-moulded with the impact-dissipating member. Also, a process for forming a helmet by in-moulding a memory foam member and an impact-dissipating material together. The in-moulding process permanently binds the memory foam member outer side to the impact-dissipating member inner side.

A method of creating a design on complex curves and irregular contours of a protective helmet, quickly and without having to first disassemble the helmet. A design is transferred to a clear film/acetate, which is then exposed onto a photoresist mask, transferring the design to the photoresist mask. The mask is washed out creating blast-able areas in the design mask. The mask is adhered to an area of the helmet, which is otherwise covered with a sealed protective bag. Sandblasting/abrasive-blasting etches portions of the helmet surface through the blast-able area of the mask. Various colors or other special effects may be painted/applied onto the etched portions of the helmet surface. The protective bag and photoresist mask can be removed, and the painted areas buffed/polished in a final step.

A method of creating a design on complex curves and irregular contours of a protective helmet, quickly and without having to first disassemble the helmet. A design is transferred to a clear film/acetate, which is then exposed onto a photoresist mask, transferring the design to the photoresist mask. The mask is washed out creating blast-able areas in the design mask. The mask is adhered to an area of the helmet, which is otherwise covered with a sealed protective bag. Sandblasting/abrasive-blasting etches portions of the helmet surface through the blast-able area of the mask. Various colors or other special effects may be painted/applied onto the etched portions of the helmet surface. The protective bag and photoresist mask can be removed, and the painted areas buffed/polished in a final step.

A method of forming a dual cure three-dimensional object by additive manufacturing may be carried out by mixing a first precursor liquid and a second precursor liquid to produce a polymerizable liquid comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component (e.g., a second reactive component) that is different from the first component (e.g., that does not contain a cationic photoinitiator, or is further solidified by a different physical mechanism, or further reacted, polymerized or chain extended by a different chemical reaction). In the foregoing: (i′) at least one reactant of the second solidifiable component is contained in the first precursor liquid, and (ii′) at least one reactant or catalyst of the second solidifiable component is contained in the second precursor liquid. Once mixed, the three-dimensional object may be formed from the resin by a dual cure additive manufacturing process.

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 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.