US 10,948,898 B1 · System and method for custom forming a protective helmet for a customer's head

Abstract

A custom-fitted helmet and a method of making the same can comprise, at a first location, obtaining head data for a customer's head comprising a length, a width, and at least one head contour. With at least one processor, generating a computerized three-dimensional (3D) headform matching the customer's head length, width, and head contour from the head data. The 3D headform can be compared to a helmet safety standard. At a second location different from the first location, a custom-fitted helmet based on the 3D headform can be formed, wherein the custom-fitted helmet satisfies the safety standard and comprises an inner surface comprising a topography that conforms to the length, width, and at least one contour of the customer's head. The first location can be a home or a store. Obtaining the head data from photographic images of a deformable interface member disposed on the customer's head.

Claims25

Dependent claims

A multi-step method of making an energy attenuation layer, comprising:

obtaining body part data from a customer's body part using a scanning device;
processing the body part data to create a computerized model of the customer's body part;
providing a computerized safety standard that includes a computerized certified surface;
positioning the computerized model of the customer's body part within the computerized certified surface of the computerized safety standard;
comparing the computerized model of the customer's body part with the computerized certified surface to assess whether the computerized model of the customer's body part extends through the computerized certified surface;
and
when said computerized model of the customer's body part does not extend through the computerized certified surface, using a three dimensional printer to form the energy attenuation layer that has an inner surface with a topography that conforms to a surface that is derived from the computerized model of the customer's body part.

4 more elements

A multi-step method of manufacturing a protective sports helmet to be worn by a player while playing a sports activity, comprising:

obtaining head data from a customer's head using a scanning device;
processing the head data to create a digital model of the customer's head;
providing a digital helmet model;
positioning the digital model of the customer's head within the digital helmet model;
generating a digital model of an energy attenuation layer that has both an inner surface that matches a surface that is derived from the digital model of the customer's head and an outer surface that is configured to be positioned within a helmet shell of the digital helmet model;
using a three dimensional printer to generate a physical energy attenuation layer from the digital model of the energy attenuation layer, and wherein the physical energy attenuation layer:
(i) is made from a polyurethane material and (ii) includes a lattice structure and an inner surface with a topography that conforms to a surface that is derived from the digital model of the customer's head;
and
installing the physical energy attenuation layer within a physical helmet shell.

6 more elements

Dependencies are inferred from the claim text.

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

Life of this patent

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

Life of this patent

Abstract

Claims25