Helmet impact monitoring system

A helmet, comprising:

• an outer shell defining an interior surface and an exterior surface;
• a cushioning layer coupled with the shell along the interior surface of the shell;
• and
• a first impact sensor coupled with one of the outer shell and the cushioning layer and including:
• a dielectric layer that is deformable in a thickness and flexible between a planar condition and a non-planar condition;
• a first printed electrode on a first side of the dielectric layer;
• and
• a second printed electrode on a second side of the dielectric layer overlying and moveable toward and away from the first electrode by deformation of the dielectric layer, the dielectric layer maintaining a capacitance between the first electrode and the second electrode, including when the dielectric layer is flexed from the planar condition into the non-planar condition, the capacitance changing with a movement of the second electrode toward or away from the first electrode;
• and
• a first readout circuit electronically coupled with the first and second electrodes to measure a change in the capacitance and output a corresponding voltage.

A method for making a protective article, comprising:

• molding an impact-protective substrate element including a non-planar portion;
• and
• coupling a first impact sensor of an impact sensing system with the impact-protective substrate element along the non-planar portion, the impact sensor including:
• a dielectric layer that is deformable in a thickness and flexible between a planar condition and a non-planar condition;
• a first printed electrode on a first side of the dielectric layer;
• and
• a second printed electrode on a second side of the dielectric layer such that the dielectric layer maintains a capacitance between the first electrode and the second electrode, including when the dielectric layer is flexed from the planar condition into the non-planar condition;
• wherein the first impact sensor conforms to the non-planar portion of the impact-protective substrate element at least by flexing of the dielectric layer.