System and method for custom forming a protective helmet for a customer's head

Abstract

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.