Custom-Fit Helmet Inner Topography from 3D Headform Data
Find Innovative SolutionsGenerate Solutions
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 based on head data, including length, width, and contour, which conforms to the user's head shape, using a deformable interface member and optical sensors, allowing for remote data capture and processing to form a helmet with an inner surface topography matching the user's head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional helmet creation technology uses head circumference as the primary sizing metric, then the helmet can be manufactured using standard sizing, but the helmet fit is poor and causes slippage and pressure points
Solution Approach 1:
The patent applies local quality by creating helmets with region-specific padding thicknesses tailored to individual head shapes. Instead of uniform sizing, the system captures 3D head geometry and manufactures helmets with varying padding densities in different zones (front, back, sides) to match the customer's specific head contours, thereby achieving precise fit without compromising manufacturing feasibility through automated customization processes
Solution Approach 2:
The patent implements preliminary action by capturing and analyzing the customer's head shape data before helmet manufacturing begins. The 3D scanning and digital modeling are performed in advance, allowing the helmet to be customized to the exact head geometry before production, ensuring precise fit while maintaining efficient manufacturing through pre-planned customization
2Manufacturing precision
If expensive scanning equipment is used to capture precise head shape data, then custom fit helmets can be manufactured, but the cost and complexity increase significantly
Solution Approach 1:
The patent employs inexpensive, portable scanning devices that can be easily transported and used in various locations (homes, retail stores). These simplified scanning systems capture sufficient 3D head geometry data without requiring expensive laboratory-grade equipment, making custom helmet fitting accessible and cost-effective while maintaining adequate manufacturing precision
Solution Approach 2:
The patent replaces complex mechanical scanning systems with optical or digital imaging technologies. Instead of using bulky mechanical scanners, the system utilizes cameras, sensors, or other non-contact optical methods to capture head shape data, thereby reducing device complexity and cost while achieving the necessary measurement accuracy for custom helmet manufacturing
3Ease of manufacture
If traditional padding adjustment methods are used to adapt standard helmets, then manufacturing remains simple, but the helmet creates pressure points and does not stabilize properly
Solution Approach 1:
The patent applies local quality by implementing region-specific padding with varying thicknesses and material densities in different zones of the helmet interior. Based on the customer's 3D head scan, the system determines optimal padding characteristics for each region (front, back, temples, crown) to distribute pressure evenly and stabilize the helmet, eliminating the pressure points and slippage caused by uniform padding in standard helmets
Solution Approach 2:
The patent implements preliminary action by calculating and preparing the precise padding configuration before helmet assembly. The 3D head geometry data is analyzed in advance to determine the exact padding thickness and density required in each zone, allowing the helmet to be manufactured with pre-optimized comfort and stability features rather than relying on post-manufacturing adjustments
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
The method enables the production of custom-fitted helmets that improve fit comfort and safety without the need for expensive scanning equipment, providing a cost-effective and practical solution for achieving a precise fit tailored to each customer's head shape.
Implementation Method 1
obtain a photographic image of 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.