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 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 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.

In a method for adapting a thermally deformable item of clothing to a body part, the item is at least partially heated and brought into contact with an abutment region and the appropriate body part. The item of clothing has a side which, in the use position, is directed towards the body and a side which, in the use position, is directed away from the body. At least one pressure-exerting unit subjects that side of the item of clothing which is directed away from the body, at least in part, to a shaping pressure such that the at least partially heated item of clothing is adapted, at least in part, to the shape of the part of the body. The item of clothing is at least partially cooled by a cooling unit such that it is stabilized in the shape adapted to the part of the body.

A method and apparatus to obtain very accurate measurements of the perimeter of a person's head scanning with an optical device; transmitting the scanned data to one or more processors which translate the measurements as precise three-dimensional data wherein an x-y plane is defined as the beginning or lower edge of the conformal cap from which a z-axis extends orthogonally in a upwardly direction towards the crown of a person's head. The three-dimensional data may be further processed to a suitable format for transmission to a transformation tool that moves one or more actuators to create an accurate three-dimensional mold of the person's head, upon which fabric or foam can be applied to create an accurate conformal cap for subsequent uses.

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.

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 for adjusting the comfort level of a helmet includes the steps of acquiring head shape data by measuring a three-dimensional shape of a head of a wearer of a helmet, inputting inner surface shape data showing a three-dimensional shape of a helmet inner surface, acquiring space information showing a space between the head and the helmet inner surface on the basis of the head shape data and the inner surface shape data, and displaying additional images showing the space information on a display part by superimposing the additional images on i) a shape image showing the inner surface shape data or ii) the shape image showing the head shape data and the inner surface shape data.

Articles and methods for obtaining measurements for the design and/or manufacture of personalized and/or customized clothing, and/or alteration of existing patterns or clothing, and for measuring and/or monitoring one or more parameters, such as size(s), shape(s) and dimension(s), of one or more aspects of a body of the wearer of the article. The articles include a stretchable material interwoven with sensors and/or conductive fibers. The articles include socks, bodysuits, bras, gloves, hats, and so forth. The personalized and/or custom-fitted clothing includes shirts, suits, pants, shorts, dresses, skirts, bras and other undergarments, sleepwear, socks, shoes, gloves, hats, exercise/active wear, protective wear (e.g., helmet, shoulder pads, body armor, etc.), and so forth. The articles and methods may further be used for health and fitness assessment.