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.

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 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.

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 present invention pertains to a system and method for creating a customized protective sports equipment, such as a football helmet or shoulder pad assembly, having improved fit for the player wearing the equipment. An electronic measuring device takes a 3D scan to obtain anatomical data and measurements of a person or player's head or torso region. The anatomical data and measurements are sent to a computer, which has software for processing the anatomical data and then evaluating that data against a set of distinct, predetermined dimensions of at least two of the same components. The component that has distinct, predetermined dimensions that best fit the anatomical data is selected for installation in the protective equipment. In this manner, a customized, player-specific selection of pre-manufactured components are used to assemble the protective equipment to be worn by the player. A multi-step process is employed to design and assemble the protective sports equipment which features stock components that have a set of predetermined dimensions, and are identified through a player-specific selection of the components.