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.

A method of producing a custom mask and strap assembly for an aviator's helmet, including: creating a custom mold using additive manufacturing based on at least two physiognomy parameters; forming the custom mask made of an elastomer from the custom mold; assembling the custom mask with a hard shell; and, securing the custom mask and the hard shell to the helmet by a strap assembly, the strap assembly including a strap anchor securable to the helmet and a strap slidably connected to the strap anchor. The strap includes a first side and a second side and further includes a first end securable to a first portion of the mask with the first side facing the mask and a second end securable to a second portion of the mask with the second side facing the mask.

Apparatus is provided for point of service manufacture of custom headwear for a subject. The apparatus comprises capture apparatus disposed at a physical location for capturing three dimensional digital data of the head of the subject and generating a three-dimensional digital data file representative of said head; an additive manufacture device located at the physical location; and a processor. The processor operates to process the three-dimensional digital data file to produce a device file comprising the shape for the custom headwear and to provide the device file to the additive manufacture device. The additive manufacture device operates to utilize the device file to manufacture the custom headwear at the physical location.

Custom manufactured headwear for a subject's head is provided. The headwear comprises 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 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.

The present invention is a system and method for creating a customized protective equipment item having improved fit. A measuring device takes measurements of a person. The measurements are sent to a computer, which has software for translating the measurements into a custom selection of standard sized components used to assemble the custom protective equipment item. An assembly process builds the completed protective equipment item which is customized to the wearer's size requirements.

A data collection, processing and fitment system for a protective sports helmet that is designed to improve: (i) the comfort and fit of the helmet, (ii) the efficiency of the design, selection and build process, and (iii) how the helmet responds when an impact or series of impacts are received by the helmet when worn by a player. In general terms, the system selects a combination of pre-manufactured energy attenuation components from a larger collection of pre-manufactured energy attenuation components that best fit the head of the player that will wear the helmet based upon data collected from the player. The system features other steps, including: creating a head model of the specific player's head from the obtained anatomical head data within a computer software program; providing a computerized helmet template that includes a helmet template reference point and a plurality of energy attenuation surfaces; aligning the head model of the player's head within the computerized helmet template; determining a plurality of energy attenuation coordinates; determining a player coordinate; determining a plurality of fit values by calculating the distance from the player coordinate to each of the plurality of energy attenuation coordinates; comparing the fit values contained in the plurality of fit values to a predefined ideal fit value; selecting the fit value that is closes to the predefined ideal fit value; identifying the pre-manufactured energy attenuation component that is associated with the selected fit value; and then installing the identified pre-manufactured energy attenuation component within the protective sports helmet.

Software for designing, configuring, and manufacturing a smart, biomechanically aware helmet is described. The software has numerous modules. One module creates instructions on designing and configuring a baseline helmet where number of shell layers, air vents, sensors, lining layer, and other features are provided. Another module is used for creating instructions on the number of energy and impact transformer layers and the mechanical and non-mechanical means used in each to absorb energy from mechanical impacts to the helmet. These dampers can include ball bearings, elastic devices, conical structures, liquids, gels, foams, and other structures that function in the transformer layers which are between the hard shell layers.

Aspects of the present disclosure provide a helmet including customized helmet layers and corresponding methods of construction. In one aspect, a method comprises capturing a 3D image of a head corresponding to the head of an individual, and rendering a 3D headform based on the 3D image. A lining layer is formed, which includes a geometry corresponding to the 3D headform and the inner surface of the shell layer such that an inner surface of the lining layer conforms to the shape of a corresponding portion of the 3D headform. An outer surface of the lining layer further conforms to the shape of a corresponding portion of an inner surface of a shell layer. Another aspect of the method comprises forming a shell layer such that the shell layer includes a geometry corresponding to the shape of a portion of the 3D headform.

A total contact helmet, including a rigid body that is customized to an individual's head for being in direct contact with the head and having a force distribution mechanism for distributing the force of an impact laterally to a large surface area of the rigid body. A method of protecting the head of an individual by the individual wearing a total contact helmet including a rigid body that is customized to the individual's head for being in direct contact with the head and having a force distribution mechanism for distributing the force of an impact laterally to a large surface area of the rigid body, 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 method of decreasing risk of concussion and head injury in an individual by wearing the total contact helmet.

A bespoke protective sports helmet to be worn by a player engaged in a sporting activity is provided. The bespoke helmet includes i) systems and methods for acquiring, storing and processing a player's unique data, namely the player's anatomical features, where that player is to wear a protective sports helmet, (ii) for systems and methods of using the player's unique data to manufacture a protective sports helmet with a custom formed internal padding assembly that substantially corresponds to the player's unique data, and (iii) a protective sports helmet designed using the acquired and processed unique player's data and including the custom formed internal padding assembly that provides improved fit and comfort for the player. The system and method allows for the design and manufacture of a bespoke protective sports helmet that is purposely designed and manufactured to match the player's anatomical specifications.