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.

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.

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.

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.

Disclosed are devices and methods for optimizing a protective helmet or other item of protective clothing with one or more enhanced principal impact zones and/or impact elements that incorporate protective features that can be particularized to a specific player-position and/or the individual behavior of a specific player or wearer.

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.

A custom-formed mesostructure for a helmet and process for designing the mesostructure are described. In one example, a process for designing a helmet for an individual can include generating a model of anthropometric aspects of a head of the individual using a scanning technique. The process can further include editing the model to generate a refined model of the anthropometric aspects of the head. The process can further include designing a mesostructure based on the refined model. The process can also include designing the mesostructure as a latticed structure having a thickness gradient that is relatively thinner along an inner periphery of the mesostructure and thicker along an outer periphery of the mesostructure, to reduce peak linear acceleration during an impact. The process can also include forming the mesostructure using an additive manufacturing technique. The mesostructure can be used independently as a helmet or combined with an outer shell.

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.

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.