System and method for forming protective sports helmet for a player engaged in a sports activity

Abstract

A protective sports helmet, such as a football helmet, to be worn by a player while playing a sports activity, such as football activities. The helmet includes a shell configured to receive a head of the player. An energy attenuation layer includes a three-dimensional (3D) printed pad member that is removably positioned adjacent to an inner surface of the helmet shell. An inner arrangement of comfort pad members, including an internal foam pad material, are positioned between the 3D printed pad member and the player's head when the helmet is worn by the player. A portion of the helmet is configured or is selected based upon analysis of head data of the player that is obtained by an electronic device that images the player's head. The 3D printed pad member is selected from a group of 3D printed pad members based upon a comparison between the player head data and data associated with each of the 3D printed pad members contained in that group.

Dependencies are inferred from the claim text.