Custom Helmet Inner Surface Shaping From Remote 3D Headforms
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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 generation from customer data, comparing it to a helmet safety standard, and forming the helmet's inner surface to conform to the customer's head contours using a deformable interface member and CNC machines, allowing for remote data capture and additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional helmet creation technology uses head circumference as the primary sizing parameter, then the helmet can be manufactured using standard molds, but the helmet fit is poor and causes slippage and pressure points
Solution Approach 1:
The patent applies local quality by creating variable thickness padding layers that are customized to match the specific contours of an individual's head. Instead of uniform padding, the system generates location-specific padding thickness values based on 3D head scanning data, allowing the helmet to conform precisely to local head shape variations while maintaining overall structural integrity
Solution Approach 2:
The system performs preliminary action by creating a digital 3D model of the customer's head before helmet manufacturing. This preliminary digital modeling allows for precise measurement and customization of padding thickness across the entire head surface, enabling the helmet to be tailored to the individual's unique head geometry prior to production
2Manufacturing precision
If expensive scanning equipment is used to capture precise head shape data, then custom fit helmets can be created, but the equipment is bulky and impractical for widespread use
Solution Approach 1:
The patent applies copying by creating a digital 3D replica of the customer's head through scanning and modeling processes. This digital copy captures all necessary geometric information about the head shape, which can then be used for customization without requiring the physical scanning equipment to be present during helmet fitting or manufacturing
Solution Approach 2:
The system replaces complex mechanical scanning equipment with a combination of optical scanning, digital imaging, and computer-based 3D modeling. This substitution transforms physical measurement challenges into digital data processing tasks, enabling precise head shape capture using more accessible and manageable technology
3Ease of manufacture
If standard helmet padding is used for all customers, then manufacturing is simplified, but the padding creates pressure points and discomfort for individual head shapes
Solution Approach 1:
The patent implements local quality by generating location-specific padding thickness values for different regions of the head. The system identifies areas where thicker padding is needed for comfort and areas where thinner padding maintains proper helmet positioning, creating a non-uniform padding distribution that adapts to individual head contours
Solution Approach 2:
The system performs preliminary action by calculating and mapping the optimal padding thickness distribution across the head surface before manufacturing. This preliminary digital modeling allows all padding specifications to be determined in advance, enabling precise customization without complicating the actual manufacturing process
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.