A method for manufacturing individualized protective gear such as pads based on a body scan, and the resulting pads, are disclosed herein. A body scan is taken of a wearer-defined area for a desired set of pads. The scan is converted to a mesh model. The mesh model is used to define a first surface of the pad shell and then translationally or orthogonally offset to provide a second surface of the pad shell. The mesh is also flattened to provide a liner for the pad. The shell may be manufactured using additive printing technology. The shell and the liner are then attached, such as by adhesive.

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.

The present disclosure relates to flexible energy absorbing systems and body armor, helmets and protective garments incorporating flexible energy absorbing systems. A flexible energy absorbing system may comprise a first plurality of cells having a first re-entrant geometry and a second plurality of cells having a second, different geometry. The first plurality of cells and the second plurality of cells may comprise an elastomeric material.

Implementations described and claimed herein include a cushioning structure and method for manufacturing a cellular cushioning system, which allows for maximum comfort through the compression and shock cycle. Specifically, a cushioning structure comprises void cells formed in an array, which comprise multiple outwardly curved surfaces, with varying radius measurements. Stiffness in the void cells can vary by varying the radii. The outwardly curved surfaces prevent buckling and provide support for high impact by absorbing energy.

A disclosed method for manufacturing a glove includes forming a base via molding, the base being shaped to include a palm portion and one or more extremity portions. The method also includes forming a top skin via molding, the top skin including one or more compartments, and forming a backhand assembly by attaching one or more edges of the one or more compartments of the top skin to the base. At least one remaining edge of each of the one or more compartments is unattached from the base. The method also includes reversing an orientation of the backhand assembly, filling each of the one or more compartments of the top skin with foam, and attaching the at least one remaining edge of each of the one or more compartments to the base.

A protective glove can include a unitary dorsal panel formed from an inner scrim material and a plurality of protective elements molded directly to an exterior surface of the inner scrim. Two or more protective elements can be formed as an array of discrete islands each separated by substantially zero-elevation interstitial spaces. The unitary dorsal panel can be sewn or otherwise attached circumferentially to the palmer sections of the glove. This array of protective elements can provide increased protection to the user's fingers, hands, wrists, and lower forearms while maintaining flexibility and tactile feel on both palmar and dorsal sides of the glove, increasing flexibility where needed without compromising protection.

There is provided a shock-absorbing assembly engageable with a human body part, such as a human head, to protect same. The shock-absorbing assembly comprises a shock-absorbing core including an inner surface configured to face at least a portion of the human body part; and a body contact seat assembly comprising: a plurality of spaced-apart resilient posts mounted to the shock-absorbing core, each one of the resilient posts having a portion protruding from the inner surface of the shock-absorbing core; and a body contact seat mounted to the shock-absorbing core via the protruding portions of the plurality of resilient posts, so that the body contact seat is in spaced relationship with the inner surface of the shock-absorbing core and at least one of slidable, displaceable, shearable and twistable with respect to the inner surface thereof. There is also provided a helmet including such a shock-absorbing assembly and a shock-absorbing kit.

A shoe or apparel, including a first material layer with a first plurality of protrusions, a flexible layer with a plurality of apertures, and a second material layer. The flexible layer is positioned between the first material layer and the second material layer. Each protrusion of the first plurality of protrusions of the first material layer extends through at least one aperture of the plurality of apertures of the flexible layer and is connected to the second material layer. The flexible layer is not connected to the first material layer and the second material layer, and thereby can freely move between the first material layer and the second material layer.

A disclosed method for manufacturing a glove includes forming a base via molding, the base being shaped to include a palm portion and one or more extremity portions. The method also includes forming a top skin via molding, the top skin including one or more compartments, and forming a backhand assembly by attaching one or more edges of the one or more compartments of the top skin to the base. At least one remaining edge of each of the one or more compartments is unattached from the base. The method also includes reversing an orientation of the backhand assembly, filling each of the one or more compartments of the top skin with foam, and attaching the at least one remaining edge of each of the one or more compartments to the base.

A shin guard includes a protective plate having a front face and a rear face. The rear face is contoured to fit around a shin of a wearer of the shin guard. Further, the shin guard includes a three dimensional image element carried on the front face. This image element projects an image outline through a sock worn over the shin guard. A sports pad is provided including an outer shell defining a pocket and a pad received and held in the pocket. A three dimensional image element is captured between said outer shell and the front face of the pad. That image element projects an image outline through the outer shell to enhance the uniform of the player wearing the sports pad.