System and method for custom forming a protective helmet for a customer's head

A computer-executed method of making a custom-fitted helmet, comprising:

• providing at least one non-contact sensor and a processor;
• using the non-contact sensor to obtain head data for a customer's head;
• providing, with a computer, a helmet safety standard that includes a certified surface;
• comparing, with said computer, the head data to the certified surface of the helmet safety standard to assess whether the obtained head data extends through the certified surface;
• and
• when said head data does not extend through the certified surface, forming a custom-fitted helmet, wherein a protective base material of the custom-fitted helmet has an inner surface with a topography that conforms to the obtained head data.

A computer-executed method of making a custom-fitted helmet, comprising:

• providing a non-contact sensor and a hardware processor;
• using the non-contact sensor at a home or at a retail store to obtain head data for a customer's head;
• and
• generating, with at least one computer, a graphical headform, said graphical headform has an outer surface that matches the head data;
• providing, with said computer, a helmet safety standard as a graphical helmet safety standard;
• positioning, with said computer, the graphical headform to satisfy the graphical helmet-safety standard and to optimize a field of view for the customer;
• and
• when said graphical helmet safety standard is satisfied, forming a custom-fitted helmet that comprises an internal padding assembly, wherein the internal padding assembly includes an inner surface with a topography that conforms to the head data for the customer's head.