Point of service method of manufacture of custom headwear

A point of service method at a clinic for fabricating an article of headwear for a subject, said method comprising:

• generating a three-dimensional digital data file for a head of said subject at said clinic by capturing a three -dimensional data file representative of said head utilizing digital image capture apparatus located at said clinic;
• utilizing, at said clinic, a processor to process said three-dimensional digital data file at said clinic by:
• automatically processing said scan data file to generate contour lines for said article of headwear on said scanned head;
• juxtaposing said modified head shape with said scanned head shape having said contour lines;
• utilizing said modified head shape data file to generate a shape for a desired article of headwear;
• projecting lines outward from said contour lines to the outer surface of said desired article of headwear;
• and
• utilizing said contour lines to produce a device file comprising the shape for said article of headwear;
• manufacturing said article of headwear at said clinic by utilizing an additive manufacture device located at said clinic.