Custom Helmet Inner Surface Fitting From 3D Headform Data
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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 requiring expensive scanning equipment and molds, leading to poor fit, comfort, and safety issues.
Innovation Solution
A method for creating custom-fitted helmets using 3D headform data, generated from images of a deformable interface member on the customer's head, which is compared to a helmet safety standard to form an inner surface topography matching the customer's head dimensions and contours, allowing for remote data capture and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional helmet creation technology uses head circumference and padding adjustments, then the helmet can be manufactured using standard methods, but the fit and comfort for individual head shapes deteriorates
Solution Approach 1:
The invention changes the parameters used for helmet sizing from simple head circumference to multiple parameters including head length, width, and contour data. This allows for more precise matching of helmet inner surface topography to individual head shapes while still using standardized manufacturing processes for the outer shell.
Solution Approach 2:
The invention performs preliminary scanning and data collection of the customer's head shape before helmet manufacturing. This preliminary action captures detailed head contour information that is then used to customize the inner surface topography, ensuring precise fit before the actual helmet production begins.
2Manufacturing precision
If expensive scanning equipment and separate molds are used for each helmet, then custom fit precision improves, but the cost and device complexity increases
Solution Approach 1:
The invention creates a digital copy or model of the customer's head shape through scanning and data processing. This digital head model is then used to generate the customized inner surface topography data, eliminating the need for physical molds for each custom helmet while maintaining precise fit.
Solution Approach 2:
The invention uses a universal scanning system that can capture head shape data and then processes this data through computer algorithms to generate customization parameters. This multi-functional approach replaces the need for separate specialized equipment for each customization step, reducing overall device complexity.
3Ease of manufacture
If conventional helmet design assumes similar human heads, then manufacturing is simplified, but the adaptability to individual head shapes deteriorates
Solution Approach 1:
The invention applies local quality by customizing only the inner surface topography of the helmet to match the individual's head shape, while the outer shell can remain standardized. This allows manufacturing simplicity to be maintained for the majority of the helmet structure while adapting to individual variations where it matters most for fit and comfort.
Solution Approach 2:
The invention segments the helmet into distinct functional parts: a standardized outer shell for protection and a customized inner surface layer for fit. This segmentation allows the outer shell to be manufactured using simple standard processes while the inner layer is customized based on individual head scanning data.
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.