An energy absorbing liner system and method of making it, preferably by thermoforming. A helmet has an energy absorbing inner system positioned inside the shell. The liner has thermoformed interconnected energy absorbing modules that non-destructively rebound after one or more impacts. At least some of the modules in the layer have a basal portion with upper and lower sections when viewed in relation to the wearer's head. The upper section has one or more energy absorbing units. At least some of the units are provided with a wall with a domed cap that faces the outer shell. The units at least partially cushion the blow by absorbing energy imparted by an object that impacts the outer shell. The lower comfort section has a tiered arrangement of layers. The layers are relatively compliant and thus provide a comfortable yet firm fit of the helmet upon the wearer.

Provided is a safety helmet that exhibits more than one color. Methods of manufacturing such safety helmets are also provided.

Partial bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The partial bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the partial bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the partial bespoke protective equipment with a partially custom formed internal padding. The system and method allows for the design and manufacture of partial bespoke protective sports equipment that is purposely designed and manufactured to substantially match the anatomical specifications of the player's body part.

A partial bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The partial bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the partial bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the partial bespoke protective equipment with a partially custom formed internal padding. The system and method allows for the design and manufacture of partial bespoke protective sports equipment that is purposely designed and manufactured to substantially match the anatomical specifications of the player's body part.

Manufacturing method of a body protection and resulting body protection, wherein the method comprises producing a structural shell (10) with a maximum thickness of 5 mm, made of thermoplastic material, and defining a concave interior (11) and a convex exterior (12); over-moulding an expanded polystyrene layer (20) overlapping the concave interior (11) of the structural shell (10), producing its adhesion by close contact to the structural shell (10); and wherein the structural shell (10) is produced by means of the distributed placement, in a mould, of a mixture of thermoplastic material and of reinforcing fibres stable at temperatures equal to or lower than the melting temperature of the thermoplastic material, the closure and heating of the mould causing the melting of the thermoplastic material without damaging the reinforcing fibres, and the subsequent cooling of the mould, hardening the thermoplastic material with the reinforcing fibres embedded therein.

A helmet, which can, for instance, be a sports helmet or a work safety helmet, comprises a helmet body composed of at least a first material and a second material different from the first material. In this respect, the helmet body comprises, on the one hand, a solid foam of expanded foam particles of the first material and, on the other hand, particles of the second material that have an adhesive connection, in particular are joined in a materially bonded manner, with at least some of the expanded foam particles of the first material.

The present invention is directed to injection molded articles as well as methods of manufacture of the same. The injection molded article is a helmet cover for a protective helmet, and more particularly a replaceable helmet cover for enhancing the aesthetic outer appearance of a helmet used in military, construction, manufacturing, and/or contact sports such as American football, baseball, lacrosse, hockey, equestrian, skiing, snowboarding, and the like.

A helmet comprising one or more additively-manufactured components designed to enhance performance and use of the helmet, such as: impact protection, including for managing different types of impacts; fit and comfort; adjustability; and/or other aspects of the helmet. Methods of additively-manufacturing components for such helmets are also provided, including methods involving expandable materials and the expansion of post-additively manufactured expandable components.

Protective headwear such as a helmet, a method of making and a method of using the same are provided. The protective headwear includes a shell having an exterior surface and an interior surface and configured to accept the head of a subject, and at least one cushioning member disposed on and at least partially covering the interior surface. The cushioning member includes a cell pack structure, which comprises a plurality of flexible cells defining a plurality of internal cavities, a plurality of channels fluidly connected with the plurality of cells to provide a network of cells, and a fluid disposed within the plurality of internal cavities and the plurality of channels. The plurality of cells comprise a first type of cells and a second type of smaller cells. The cells and the channels are made of the same or different materials.

A partial bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The partial bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the partial bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the partial bespoke protective equipment with a partially custom formed internal padding. The system and method allows for the design and manufacture of partial bespoke protective sports equipment that is purposely designed and manufactured to substantially match the anatomical specifications of the player's body part.