Removeable helmet cover and methods of manufacture

A method of manufacturing a helmet cover, wherein the helmet cover comprises a unitary shell assembly comprising a receiving cavity, an interior surface, and an exterior surface, wherein the receiving cavity is configured such that the interior surface of the unitary shell assembly is configured to contact an exterior surface of a helmet and wherein the unitary shell assembly fittably and detachably covers the exterior surface of the helmet, the method comprising:

• A. providing a polymeric injection unit comprising:
• (i) a barrel-mounted screw assembly, wherein the barrel-mounted screw assembly comprises a screw mounted within a barrel;
• (ii) a processing space, wherein the processing space comprises a distal end and a proximal end;
• and
• (iii) one or more nozzles in fluid communication with the processing space, wherein the one or more nozzles are located at the distal end of the processing space;
• B. providing an injection mold tool, wherein the injection mold tool comprises a mold cavity in fluid communication with the one or more nozzles and wherein the injection mold tool is structured so as to form the helmet cover in a single piece, and wherein providing the injection mold tool comprises at least the following steps;
• (i) scanning the helmet to obtain a helmet geometry file;
• (ii) altering the helmet geometry file to form a helmet cover geometry file, wherein altering the helmet geometry file includes at least the following steps;
• 1. Manipulating the size of the helmet depicted in the helmet geometry file by expanding it in all directions in an amount that is equivalent to the desired thickness of the helmet cover;
• and
• 2. manipulating the shape of the helmet depicted in the helmet cover geometry file by shaving the interior surface depicted in the helmet geometry file to create an end product with a total thickness equivalent to the desired thickness of the helmet cover;
• (iii) printing a 3-dimensional helmet cover prototype;
• (iv) adjusting the helmet cover geometry file;
• and
• (v) creating the injection mold tool using the helmet cover geometry file,
• wherein adjusting the helmet cover geometry file includes providing an improved fit of the helmet cover as compared to the 3-dimensional helmet cover prototype;
• C. introducing a polymeric material into the processing space;
• D. melting the polymeric material within the processing space, wherein the melting is achieved by using the screw mounted within the barrel to mix the polymeric material and applying a heat source to bring the polymeric material to a first predefined temperature and to create a predefined backpressure;
• E. injecting a volume of the polymeric material through the one or more nozzles and into the mold cavity, wherein the volume of the polymeric material is sufficient to fill the mold cavity;
• F. cooling the polymeric material within the mold cavity to a second predefined temperature;
• and
• G. extracting the polymeric material within the mold cavity from the injection mold tool to provide the helmet cover.