Protective gear includes an outer shell layer connected to a middle shell layer through an outer energy and impact transformer layer. The middle shell layer is connected to an inner shell layer through an inner energy and impact transformer layer. The outer and inner energy and impact transformer layers flexibly connect the shell layers to absorb impact forces, rotational forces, shear forces, etc., and allow the various shell layers to move and slide relative to the other shell layers. The outer and inner energy and impact transformer layers may be constructed using gels, fluids, electro-rheological elements, magneto-rheological elements, etc. The protective gear may be formed as helmets or body protection for various activities and protect users from not only impact and penetrative forces, but rotational and shear forces as well.

A system for monitoring a physiological parameter of player wearing protective sports equipment. The monitoring system includes a monitoring unit configured to be positioned within a piece of protective sports equipment worn by a player and transmit physiological parameter data to a database. A database is configured to receive and store the transmitted physiological parameter data. A server is configured to automatically generate a report after a predetermined time interval, where the report has at least one training opportunity indicator and a portion of the received and stored physiological parameter data. The training opportunity indicator is generated when the transmitted physiological parameter data exceeds a predetermined threshold that is based on a previously recorded collection of physiological parameter data. That physiological parameter data can be: the player's own historical data, a team's historical data, a sum of alertable impacts from other similarly situated players, and/or a sum of alertable impacts the player has received over the alertable time period.

The invention relates to a protective sports helmet purposely designed using a multi-step method for a selected group of helmet wearers from amongst a larger population of helmet wearers. The protective sports helmet can be a position specific American football helmet that includes a shell, a facemask coupled to the shell, and an energy attenuation assembly configured to be positioned within the shell. The specific playing position can be a football quarterback such that the football helmet absorbs a larger amount of force from an impact applied to a rear portion of the inventive helmet as compared to the amount of force absorbed by a frontal portion of that helmet from the same impact applied thereto. Alternatively, the specific playing position can be a football lineman such that the football helmet absorbs a larger amount of force from an impact applied to a front portion of the helmet as compared to the amount of force absorbed from the same type of impact applied to a front portion of a non-position specific American football helmet.

A method for producing a customized helmet including a computer designed composite helmet liner to be incorporated into existing and new helmet designs is provided by scanning a user's cranial region, creating a computer rendering surface model of the scan, modifying the surface model using computer aided design software, overlaying and aligning an outer helmet shell model onto the modified cranial model to define the custom liner three-dimensional space to configure the composite liner with a software algorithm including shock absorbing segments having optimal sizes, shapes, and materials, fabricating the liner in a heat sealing process to include an optional encapsulating or serial air bladder, and assembling the liner and outer helmet shell together.

A method of generating a topographic map of a region of a body for the manufacture of a body fitting article to be fitted to the region of the body. The method allows for the resultant topographical map of the body feature to be coupled to an anatomical and functional datum on the body. The method involves use of a contact probe which is configured to generate positional data which defines the surface it is drawn across. The method comprises the steps of urging a contact probe towards the outer surface of the body such that the contact probe is touching the outer surface of the body or separated from the outer surface of the body only by a barrier layer which is flattened against the outer surface of the body by the probe. The contact probe is drawn over the region of the body where the body fitting article is to be located such that the contact probe generates 3D positional data of the surface of the outer surface of the body in the region of the body where the body fitting article is to be located.

A custom-fitted protective sports equipment 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 safety standard. At a second location different from the first location, the custom-fitted protective sports equipment is 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 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.

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.