Custom Helmet Inner Surface Shaping for Precise Head Fit
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Solution Overview
Problem
Conventional helmet creation technologies fail to provide a comfortable and secure fit for individual head shapes due to reliance on head circumference measurements, leading to issues like slippage, rattling, and pressure points, and require expensive scanning equipment and molds.
Innovation Solution
A method for custom-fitting helmets by obtaining head data for length, width, and contours, generating a 3D headform, and forming a helmet with an inner surface that conforms to these measurements, using a deformable interface member and optical sensors, and a CNC machine to create a personalized fit without separate molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional helmet creation uses head circumference measurements and standard padding adjustments, then the helmet can be manufactured using simple methods, but the helmet does not fit correctly and creates pressure points or slippage
Solution Approach 1:
The patent creates a digital 3D copy of the customer's head using optical scanning technology. This digital head model serves as a precise template for customizing the helmet inner surface, eliminating the need for complex physical scanning equipment and molds while achieving high manufacturing precision
Solution Approach 2:
The patent uses a single optical scanning system that can capture complete head geometry data without requiring multiple measurement tools or physical contact. The digital model generated serves multiple purposes: fit analysis, customization template, and manufacturing guide, replacing numerous specialized devices
2Manufacturing precision
If expensive scanning equipment and separate custom molds are used for each helmet, then custom head shape helmets can be created, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
Instead of creating physical custom molds for each customer, the patent generates a digital 3D copy of the head and uses this digital model to customize the helmet inner surface through software-controlled manufacturing processes, eliminating the need for expensive physical mold fabrication
Solution Approach 2:
The patent replaces the mechanical mold-making process with a digital design and manufacturing approach. Optical sensors capture head geometry, software processes the data to create a digital model, and computer-controlled systems manufacture the customized helmet, substituting manual mold creation with automated digital processes
3Adaptability or versatility
If standard helmets with adjustable padding are used, then the helmets can accommodate different head sizes, but they cannot eliminate pressure points or slippage for individual head shapes
Solution Approach 1:
The patent customizes the helmet inner surface to match the specific local geometry of the customer's head. Rather than using uniform padding adjustments, the system creates region-specific contours that conform to individual head shape variations, eliminating pressure points while maintaining overall size accommodation
Solution Approach 2:
The patent creates a dynamic fit solution where the helmet inner surface is specifically adapted to the customer's head geometry. The digital modeling process captures the unique dynamics of how the head interacts with the helmet, allowing for personalized contact points and pressure distribution rather than static one-size-fits-all padding
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides a secure and comfortable helmet fit by matching the helmet's inner surface to the individual's head shape, ensuring compliance with safety standards while reducing the need for expensive scanning and manufacturing equipment.
Implementation Method 1
obtaining images of a deformable interface member disposed on the customer's head
Data Source
AI summary
A custom-fitted protective sports equipment 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 safety standard. At a second location different from the first location, the custom-fitted protective sports equipment is 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.