System and methods for designing and manufacturing bespoke protective sports equipment
A bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the bespoke protective equipment with a custom formed internal padding assembly that substantially corresponds to the player's unique data. The system and method allows for the design and manufacture of bespoke protective sports equipment that is purposely designed and manufactured to match the anatomical specifications of the player's body part.
1. A method for manufacturing a bespoke protective sports helmet to be worn by a player while playing a sports activity, comprising:
performing a scan of a player's head with the scanning apparatus;
aligning the scan relative to a reference surface, wherein said reference surface is associated with a selected helmet size within the three-dimensional software;
comparing the aligned scan of the player's head against the reference surface of the selected helmet size within the three-dimensional software to confirm that the scan does not penetrate the reference surface;
inwardly adjusting the aligned scan of the player's head by a predetermined amount within the three-dimensional software to create a modified scan of the player's head;
forming a bespoke pad based on the modified scan of the player's head; and
installing the bespoke pad into a protective sports helmet shell.
2. The method for manufacturing the bespoke protective sports helmet according to claim 1 , wherein the step of inwardly adjusting the aligned scan of the player's head results in an increase of the thickness of the bespoke pad.
3. The method for manufacturing the bespoke protective sports helmet according to claim 1 , wherein the step of aligning the scan relative to the reference surface includes adjusting the scan based on the player's playing position or playing level.
4. The method for manufacturing the bespoke protective sports helmet according to claim 3 , wherein adjusting the scan based on the player's playing position or playing level includes moving the scan either forward or backward in comparison to the location of the aligned scan based on the player's playing position or playing level.
5. The method for manufacturing the bespoke protective sports helmet according to claim 1 , wherein the step of aligning the scan relative to the reference surface includes adjusting the scan based on data collected from the player's on-field wearable monitoring system.
6. The method for manufacturing the bespoke protective sports helmet according to claim 5 , wherein adjusting the scan based on data collected from the player's on-field wearable monitoring system includes moving the scan either forward or backward in comparison to the location of the aligned scan based on data collected from the player's on-field wearable monitoring system.
7. The method for manufacturing the bespoke protective sports helmet according to claim 1 , wherein the step of capturing a scan of a player's head with the scanning apparatus includes:
placing a scanning hood on the player's head; and
acquire images of portions of the player's head and portions of a scanning hood overlying the player's head.
8. The method for manufacturing the bespoke protective sports helmet according to claim 7 , wherein the step of capturing a scan of a player's head with the scanning apparatus includes stitching together images of portions of the player's head and portions of a scanning hood overlying the player's head to generate a three-dimensional representation of the player's head.
9. The method for manufacturing the bespoke protective sports helmet according to claim 7 , wherein the step of capturing a scan of a player's head with the scanning apparatus further includes:
selecting a scanning helmet size;
placing a scanning helmet of the selected scanning helmet size on the player's head over the scanning hood;
capturing a helmet scan of the player wearing the scanning hood and scanning helmet with a scanning apparatus; and
removing the scanning helmet from the player's head and capturing a hood scan with the scanning apparatus while the player is wearing the scanning hood.
10. The method for manufacturing the bespoke protective sports helmet according to claim 1 , wherein the step of forming a bespoke pad based on the modified scan of the player's head includes selecting a compression deflection rating of the at least one pad member is selected based on at least one of the following factors: i) player's impact history, ii) player's skill level, or iii) player's position.
11. The method for manufacturing the bespoke protective sports helmet according to claim 1 , further comprising the step of adding an identification device to the bespoke pad.
12. A method for manufacturing a bespoke protective sports helmet to be worn by a player while playing a sports activity, comprising:
capturing a scan of a player's head with the scanning apparatus;
aligning the scan relative to a reference surface that is associated with a selected helmet size within the three-dimensional software;
modifying the aligned scan of the player's head based on the player's playing position or playing level to create a modified scan of the player's head that includes moving the aligned scan of the player's head either towards a front region or a rear region of the helmet;
forming a bespoke pad based on the modified scan of the player's head; and
installing the bespoke pad into a protective sports helmet shell.
13. The method for manufacturing the bespoke protective sports helmet according to claim 12 , further comprising the step of inwardly adjusting the aligned scan of the player's head by a predetermined amount after the scan is confirmed not to penetrate the reference surface.
14. The method for manufacturing the bespoke protective sports helmet according to claim 13 , wherein the step of inwardly adjusting the aligned scan of the player's head results in an increase of the thickness of the bespoke pad that is installed in the protective sports helmet.
15. The method for manufacturing the bespoke protective sports helmet according to claim 12 , further comprising the step of comparing the modification of the aligned scan of the player's head against a reference surface of the selected helmet size within the three-dimensional software to confirm that the scan does not penetrate the reference surface.
16. The method for manufacturing the bespoke protective sports helmet according to claim 12 , wherein the step of capturing a scan of a player's head with the scanning apparatus includes:
placing a scanning hood on the player's head; and
acquire images of portions of the player's head and portions of a scanning hood overlying the player's head.
17. The method for manufacturing the bespoke protective sports helmet according to claim 16 , wherein the step of capturing a scan of a player's head with the scanning apparatus includes stitching together images of portions of the player's head and portions of a scanning hood overlying the player's head to generate a three-dimensional representation of the player's head.
18. The method for manufacturing the bespoke protective sports helmet according to claim 16 , wherein the step of capturing a scan of a player's head with the scanning apparatus further includes:
selecting a scanning helmet size;
placing a scanning helmet of the selected scanning helmet size on the player's head over the scanning hood;
capturing a helmet scan of the player wearing the scanning hood and scanning helmet with a scanning apparatus; and
removing the scanning helmet from the player's head and capturing a hood scan with the scanning apparatus while the player is wearing the scanning hood.
19. The method for manufacturing the bespoke protective sports helmet according to claim 12 , wherein the step of forming a bespoke pad based on the modified scan of the player's head includes selecting a compression deflection rating of the at least one pad member is selected based on at least one of the following factors: i) player's impact history, ii) player's skill level, or iii) player's position.
20. The method for manufacturing the bespoke protective sports helmet according to claim 12 , further comprising the step of adding an identification device to the bespoke pad.
21. A method of assembling a protective sports helmet to be worn by a player while participating in a sports activity, comprising:
placing a scanning helmet on the player's head;
capturing a helmet scan of the player wearing the scanning helmet;
removing the scanning helmet from the player's head;
capturing a head scan of the player head;
aligning the head scan relative to the helmet scan to form a registered head scan within a three-dimensional software;
comparing the registered head scan of the player's head against a reference surface within the three-dimensional software to confirm that the head scan does not penetrate the reference surface;
inwardly adjusting the registered head scan of the player's head by a predetermined amount within the three-dimensional software to create an inset head scan;
selecting a pad from a group of pads based on the inset head scan; and
installing the selected pad into a protective sports helmet shell.
22. The method of assembling the protective sports helmet according to claim 21 , wherein the step of inwardly adjusting the registered head scan of the player's head by a predetermined amount results in an increased thickness of the selected pad that is installed in the protective sports helmet.
23. The method of assembling the protective sports helmet according to claim 21 , wherein the step of selecting the pad from the group of pads based on the inset head scan includes comparing the physical characteristics of each pad in the group of pads against the inset head scan and the helmet shell.
24. The method of assembling the protective sports helmet according to claim 23 , wherein the physical characteristics of each pad in the group of pads include thickness and compression deflection.
25. The method of assembling the protective sports helmet according to claim 21 , wherein the step of selecting the pad from the group of pads based on the inset head scan includes selecting the pad with a thickness rating that accounts for information obtained based upon at least one of the following factors: i) player's impact history, ii) player's skill level, or iii) player's position.
26. The method of assembling the protective sports helmet according to claim 21 , wherein the step of selecting the pad from the group of pads based on the inset head scan includes selecting the pad with a compression deflection rating that accounts for information obtained based upon at least one of the following factors: i) player's impact history, ii) player's skill level, or iii) player's position.