# US 2019/0167463 A1 · Custom headwear manufactured by additive manufacture

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- Number: US 2019/0167463 A1
- Document ID: US20190167463A1
- Status: Published application
- Kind: A1
- Application number: 16/266,791
- Filed: 2019-02-04
- Published: 2019-06-06
- Earliest claimed: 2017-03-30
- Assignees: Cranial Technologies, Inc.
- Applicants: Cranial Technologies, Inc.
- Inventors: TIMOTHY R LITTLEFIELD; JEROLD N LUISI; GEORGE E KECHTER
- Web page: https://patentgrep.com/patent/US20190167463A1

## CPC

- A61F 5/05891: {for the head, e.g. jaws, nose (nose correcting A61F5/08)}
- A42B 3/063: {using layered structures}
- A42C 2/007: {Manufacturing custom-sized helmets}
- A61B 5/11: Measuring movement of the entire body or parts thereof, e.g. head or hand tremor or mobility of a limb {(A61B5/1038 takes precedence; motion detection to correct for motion artifacts in physiological signals A61B5/721)}
- A63B 71/10: for the head ({A63B71/081 takes precedence } ; in the form of caps or hats A42B1/08; helmets A42B3/00)
- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- B33Y 80/00: Products made by additive manufacturing
- B29L 2031/4807: {Headwear}
- B29L 2031/753: {Medical equipment; Accessories therefor (bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008)}
- F41H 1/04: Protection helmets (crash helmets A42B3/00)
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)
- A42B: HATS; HEAD COVERINGS (headbands A41D20/00; head-scarves A41D23/00)
- A42C: MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
- A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D)
- A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- F41H: ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL

## Abstract

Custom manufactured headwear for a subject's head is provided. The headwear comprises an inner layer deposited by an additive manufacturing device. The headwear further comprises an outer layer deposited by the additive manufacturing device. The inner layer and the outer layer are each formed by the additive manufacture device utilizing a device data file derived from a subject data file. The subject data file is representative of the shape of the head and the device data file determining the shape of the headwear.

## Claims

### Claim 1

Custom manufactured headwear for a subject, comprising:
a first layer shaped to contact the head of said subject at predetermined areas, said first layer formed by additive manufacturing;
an outer layer containing said first and second layers; and
a second layer formed by additive manufacturing said second layer disposed intermediate said first layer and said outer layer, said second layer comprising a cellular configuration.

### Claim 2 (depends on 1)

The custom headwear of claim 1, comprising:
said first layer and said second layer are each formed utilizing a device data file, said device data file derived from a subject data file, said subject data file representative of the shape of a head of said subject; and
at least one of said second layer and said outer layer comprising carbon fibers.

### Claim 3 (depends on 2)

The custom headwear of claim 2, comprising:
said device data file comprises contour lines for said custom headwear.

### Claim 4 (depends on 3)

The custom headwear of claim 3, wherein:
each of said first layer, said second layer, and said outer layer comprise contour lines determined by said device data file contour lines.

### Claim 5 (depends on 4)

The custom headwear of claim 4, comprising:
said device data file is derived by one or more processors:
determining contour lines for said custom headwear on a digital representation of said shape of said head utilizing said subject data file;
juxtaposing a digital representation of said headwear on a digital representation of said shape of said head;
projecting lines outward from said contour lines of said digital representation of said shape of said head to determine headwear contour lines for said first layer, said second layer and said outer layer; and
utilizing said headwear contour lines to produce said device file.

### Claim 6 (depends on 1)

The custom headwear of claim 1, wherein:
said second layer comprises portions positioned to contact said head at predetermined surface areas of said head.

### Claim 7 (depends on 1)

The custom headwear of claim 1, comprising:
said first layer comprises a plurality of separate portions, each portion configured to contact one of a corresponding plurality of areas on said head.

### Claim 8 (depends on 1)

The custom headwear of claim 1, comprising:
said second layer comprises a cellular construction.

### Claim 9 (depends on 8)

The custom headwear of claim 8, wherein:
said second layer comprises carbon fibers.

### Claim 10 (depends on 1)

The custom headwear of claim 1, comprising:
said first layer, said second layer and said outer layer each comprise one or both of different strength and material properties.

### Claim 11 (depends on 1)

The custom headwear of claim 1, wherein:
said second layer comprises carbon fibers.

### Claim 12 (depends on 1)

The custom headwear of claim 1, wherein:
at least one of said first layer, said second layer, and said outer layer comprise carbon fibers.

### Claim 14

Custom manufactured headwear for a head of a subject, comprising:
an inner layer formed by additive manufacturing, said inner layer comprising a cellular configuration;
an outer layer containing said inner layer, said outer layer formed by additive manufacturing; and
said inner and said outer layer each comprising custom contour lines.

### Claim 15 (depends on 14)

The custom manufactured headwear of claim 14, wherein:
said inner layer comprises carbon fibers.

### Claim 16 (depends on 14)

The custom headwear of claim 14, comprising:
said inner layer is formed by utilizing a device data file derived from a subject data file, said subject data file representative of the shape of said head.

### Claim 17 (depends on 16)

The custom headwear of claim 16, wherein:
said device data file comprises said contour lines, said contour lines developed from said subject data file.

### Claim 18 (depends on 17)

The custom headwear of claim 17, comprising:
said outer layer is formed by additive manufacturing utilizing said device data file

### Claim 19 (depends on 18)

The custom headwear of claim 18, wherein:
at least one of said inner and outer layer comprises carbon fibers.

### Claim 20 (depends on 16)

The custom headwear of claim 16, comprising:
said device data file is derived by one or more processors operated to:
determine contour lines for said custom headwear on a digital representation of the subject head shape defined by said subject data file;
juxtaposing a digital representation of said headwear on said digital representation of said subject head shape;
projecting said contour lines outward from said subject head shape onto said digital representation of said headwear; and
utilizing said projected contour lines to produce said device file.

### Claim 21 (depends on 14)

The custom headwear of claim 14, comprising:
a first layer comprising portions positioned to contact said head at predetermined surface areas of said head, said inner layer disposed between said first layer and said outer layer.

### Claim 22 (depends on 21)

The custom headwear of claim 21, comprising:
said first layer comprises a plurality of separate portions, each portion configured to contact one of a corresponding plurality of areas on said head.

### Claim 23 (depends on 22)

The custom headwear of claim 22, wherein:
said first layer, said second layer and said outer layer each comprise one or both of different strength and material properties.

### Claim 24 (depends on 14)

The custom headwear of claim 14, comprising:
said inner layer and said outer layer each comprise one or more of different strength properties, material properties, and configurations.