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 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).

A custom-fitted helmet 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 helmet safety standard. At a second location different from the first location, a custom-fitted helmet based on the 3D headform can be 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 first location can be a home or a store. Obtaining the head data from photographic images of a deformable interface member disposed on the customer's head.

Custom manufactured headwear for a subject's head includes an inner layer shaped to contact the head of the subject at predetermined areas. The inner layer is deposited by an additive manufacturing device. The headwear further includes 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 determines the shape of the headwear.

A total contact helmet, including a body that is customizable to an individual's head and having force distribution means for distributing the force of an impact to a large surface area of the body. A total contact helmet insert, including a body that is customizable to an individual's head and having force distribution means for distributing the force of an impact to a large surface area of the body, the total contact helmet insert being insertable under an existing helmet or as an inner shell as part of an existing helmet. A method of protecting the head of a user by the user wearing the total contact helmet, and when receiving an outside impacting force to the total contact helmet, distributing the force of impact over the surface area of the total contact helmet.

A custom-fitted helmet 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 helmet safety standard. At a second location different from the first location, a custom-fitted helmet based on the 3D headform can be 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 first location can be a home or a store. Obtaining the head data from photographic images of a deformable interface member disposed on the customer's head.

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.

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 may be worn on a head of a wearer having a shape and a contour. The helmet may have a plurality of layers coupled together including an energy management layer and an outer shell layer disposed over the energy management layer. The plurality of layers are integrally formed with one another, and the energy management layer is configured to absorb and dissipate energy received by the helmet during an impact by an external force. The outer shell layer is configured to disperse and dissipate impact energy from the external force. Each of the plurality of layers has a density and a geometry, and the density or geometry of at least one layer differs from the density or geometry of at least another layer.

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.