An article of protective apparel can include a first outer shell having a vacuum-formed first material. The first outer shell can include a first cavity, a second cavity, and a channel disposed between the first cavity and the second cavity. The protective apparel can include a first padding piece disposed in the first cavity, a second padding piece disposed in the second cavity, and a first inner layer attached to the first outer shell. the first padding piece and the second padding piece can be disposed between the first outer shell and the first inner layer.

A body impact protection system includes an inner layer and an impact force dampening and defusing structure. The inner layer includes a material composition and is adjacent to a body part when the body impact protection system is worn. The impact force dampening and defusing structure is juxtaposed to the inner layer and includes a plurality of components. The components function to reduce pressure on the body part from an impact force on a layer by layer basis. Each layer of the system dampens and defuses the impact force such that, by the time it reaches the body part, it has been substantially attenuated and spread over a large area.

A protective shield for a lower leg of an ice skater is provided. The protective shield comprises a protective segment and a support segment to which the protective segment is secured. The protective segment comprises a web of interlocking metal loops. The protective segment is shaped and sized to fit over at least a rear portion of the lower leg including at least a portion of an Achilles tendon and at least a portion of a calf. The support segment is shaped and sized to fit around the lower leg, and is resilient to hold the protective shield in place around the lower leg during skating and to tension the protective segment against the rear portion of the lower leg.

An article of apparel includes a padding system that dynamically changes configuration in response to an impending impact. The padding system may change from a state that has a high flexibility and offers low protection from impact to a state that has a low flexibility and offers increase protection from impact. The system may use a filament to constrict a plurality of padding elements together in order to increase the overall stiffness of the pad. The filament may be tightened and loosened by a spool. The spool may receive a signal regarding the impending impact from a sensor that is a part of the article of apparel, or a sensor that is separate from it.

A body impact protection system includes an inner layer and an impact force dampening and defusing structure. The inner layer includes a material composition and is adjacent to a body part when the body impact protection system is worn. The impact force dampening and defusing structure is juxtaposed to the inner layer and includes a plurality of components. The components function to reduce pressure on the body part from an impact force on a layer by layer basis. Each layer of the system dampens and defuses the impact force such that, by the time it reaches the body part, it has been substantially attenuated and spread over a large area.

A body limb protection system includes an outer layer, an inner layer, and a force dampening and defusing structure. The outer layer includes a first material composition and has an exterior surface that includes a substantially planer area. The inner layer includes a second material composition and has a shape corresponding to a body limb portion. The force dampening and defusing structure is positioned between the inner layer and the outer layer. The force dampening and defusing structure has a shape corresponding to a difference between the shapes of the inner and outer layers. The force dampening and defusing structure includes a plurality of components arranged to reduce pressure on the body limb portion when a force is applied to the substantially planer area.

An impact force dampening and defusing structure includes a plurality of components arranged in a grid array. A component has a three-dimensional geometric shape that includes an impact receiving surface area and an impact defusing surface area. The impact defusing surface area is larger than, and a distance d from, the impact receiving surface area. The component includes a material composition and, when an impact force strikes the impact receiving surface area of the component and the impact force dampening and defusing structure is in position to protect a body part, the component contributes to reducing pressure on the body part based on the material composition, the distance d, the impact receiving surface area, and the impact defusing surface area.

A force defusing structure includes first and second plurality of spherical shaped objects. A first spherical shaped object is proximally positioned to two or more second spherical shaped objects. When a force is applied to the first spherical shaped object, the first spherical shaped object collides with the two or more second spherical shaped objects to defuse the force based on a multi-dimensional collision between the first spherical shaped object and the two or more second spherical shaped objects.

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.

An article of apparel for a human being, designed or arranged to be worn around an appendage such as an arm or leg, and designed or intended to resist impact. The article contains a material in the form of a spongy, elastic polymer engineered to absorb energy, shock, vibration and impact. The article of apparel can be used to protect hard, bony areas of the human body such as elbows, knees and ankles. The article will be of use to persons engaged in sports involving bats, sticks, mallets, pucks and hard balls, as well as to cyclists, and anyone whose occupation requires the knees or elbows to come into contact with hard surfaces.