Methods for manufacturing individualized protective gear from scan and resulting products

A method for fabricating equipment having a shell portion and a liner portion to be worn by a wearer, comprising:

• a) selecting a garment comprising a pocket with a visibly defined border;
• b) donning the garment on the wearer's body;
• c) obtaining a scan of at least a portion of the garment at the location where the pocket is disposed over the wearer's body;
• d) preparing a wearer mesh model derived from the scan at the location where the pocket is disposed over the wearer's body;
• e) preparing a model of the shell, the shell having a first surface defined by the wearer mesh model and a second surface translationally offset from and identical to the first surface;
• f) checking the model of the shell to identify production defects and, if a production defect is present, removing the defect;
• g) preparing a model of a liner by flattening the model of the shell;
• h) additively manufacturing the shell;
• i) manufacturing the liner;
• and
• j) attaching the liner to the shell.