Custom Helmet Inner Surface Using 3D Headform Replication
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Solution Overview
Problem
Conventional helmet creation technologies fail to provide a custom fit for individual head shapes, relying on head circumference and resulting in poor fit, slippage, and pressure points, while existing scanning systems are expensive, bulky, and impractical for widespread use.
Innovation Solution
A method for creating custom-fitted helmets using 3D headform data, where head data is obtained through deformable interface members and processed to generate a computerized 3D model, allowing for the formation of a helmet inner surface that conforms to the customer's head shape, size, and contour, using a CNC machine and additive processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional helmet creation technology uses head circumference and standard sizing, then helmets can be mass-produced with simple manufacturing processes, but the helmets do not fit correctly, slip around, rattle, or create pressure points on individual heads
Solution Approach 1:
The patent applies preliminary action by creating a 3D digital model of the customer's head before helmet manufacturing. The head scanning and 3D modeling are performed in advance to capture precise head geometry, which then guides the custom helmet fabrication process. This preliminary digital representation enables precise fitting without requiring complex physical trial-and-error adjustments during manufacturing.
Solution Approach 2:
The patent uses copying by creating a digital 3D replica of the customer's head through scanning and modeling. This digital copy serves as the basis for designing and manufacturing the custom helmet, replacing the need for physical head forms or molds. The digital model accurately reproduces head contours and can be used to generate precise manufacturing instructions for the custom helmet interior surface.
2Measurement precision
If expensive scanning equipment is used to capture head data, then accurate 3D headform data can be obtained, but the equipment is bulky, difficult to transport, and requires trained personnel
Solution Approach 1:
The patent applies this principle by using inexpensive, disposable-like measurement methods such as photographing a deformable interface member (cap) worn on the head. Instead of requiring expensive, sophisticated scanning equipment, the system uses simple cameras and 2D imaging to capture head shape data. The deformable cap acts as a temporary, low-cost measurement medium that can be easily removed and replaced, eliminating the need for complex, expensive scanning infrastructure.
Solution Approach 2:
The patent replaces complex mechanical scanning systems with a simpler optical-based approach. Instead of using bulky mechanical scanners that require trained operators, the system uses 2D photographs taken with standard cameras. The mechanical complexity of traditional scanning equipment is substituted with optical capture and digital image processing, making the measurement process more accessible and easier to operate.
3Manufacturing precision
If custom molds are created for each helmet, then each helmet can be perfectly fitted to the customer's head, but the manufacturing cost and time increase significantly
Solution Approach 1:
The patent uses digital copying to eliminate the need for physical custom molds for each helmet. A digital 3D model of the head is created once, and this digital copy can be used repeatedly to generate manufacturing instructions for multiple helmets. The digital model serves as a reusable template that maintains custom fit precision while enabling efficient production, as the same digital data can be used to manufacture multiple helmets without creating multiple physical molds.
Solution Approach 2:
The patent applies parameter changes by transitioning from physical mold-based manufacturing to digital model-based manufacturing. The key parameter change is moving from tangible, custom-made molds to intangible, reusable digital 3D models. This parameter change allows the system to maintain custom fit precision while dramatically improving productivity, as digital models can be stored, retrieved, and used for manufacturing multiple helmets without the time and cost of creating new physical molds for each customer.
Data Source
AI summary
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.