SYSTEM AND METHOD FOR CUSTOM FORMING A PROTECTIVE HELMET FOR A CUSTOMER'S HEAD
A custom-fitted helmet and a method of making the same can comprise, at a first location, obtaining head data for a customer's head comprising a length, a width, and at least one head contour. With at least one processor, generating a computerized three-dimensional (3D) headform matching the customer's head length, width, and head contour from the head data. The 3D headform can be compared to a helmet safety standard. At a second location different from the first location, a custom-fitted helmet based on the 3D headform can be formed, wherein the custom-fitted helmet satisfies the safety standard and comprises an inner surface comprising a topography that conforms to the length, width, and at least one contour of the customer's head. The first location can be a home or a store. Obtaining the head data from photographic images of a deformable interface member disposed on the customer's head.
1 . A custom-fitted protective sports helmet worn by a wearer engaged in a sporting activity, the helmet comprising:
a shell configured to receive a head of the wearer of the custom-fitted helmet, the shell having two side regions that are configured to overlie an extent of the wearer's cheek when the helmet is worn by the wearer; and
a three dimensional printed energy attenuation liner assembly removably positioned within the shell, wherein the energy attenuation liner assembly includes:
(i) an outer surface that resides adjacent to an inner surface of the shell,
(ii) an inner surface that substantially conforms to a computerized representation of an outer surface of the wearer's head; and,
(iii) a non-uniform liner thickness with that ensures that the computerized representation of the outer surface of the wearer's head does not extend through a predetermined certified surface that is associated with a computerized representation of the shell.
2 . The custom-fitted protective sports helmet of claim 1 , wherein the energy attenuation liner assembly includes a lattice structure.
3 . The custom-fitted protective sports helmet of claim 2 , further includes a faceguard that is secured to the shell by at least two face guard connectors.
4 . The custom-fitted protective sports helmet of claim 2 , wherein the helmet is football helmet that includes non-circular openings that are positioned within the side regions of the shell.
5 . The custom-fitted protective sports helmet of claim 1 , wherein the energy attenuation liner assembly includes a plurality of separate members that are formed outside of the shell.
6 . The custom-fitted protective sports helmet of claim 1 , wherein the computerized representation of the wearer's head is created using data acquired from a scanning device, said scanning device includes a processor, a non-contact sensor, and a software program that prompts a person to acquire data about the wearer's head using the non-contact sensor.
7 . The custom-fitted protective sports helmet of claim 6 , wherein the software program adjusts a number of images or a length of the video taken in order to ensure sufficient data is acquired to generate the computerized representation of the wearer's head.
8 . The custom-fitted protective sports helmet of claim 1 , wherein the predetermined certified surface that is associated with a computerized representation of the custom-fitted helmet is a part of a three-dimensional helmet safety standard that is determined by a regulatory governing body.