Patent ID: 7234812

Claim:
A method of manufacturing a helmet with an optical display system, wherein the helmet is custom fitted to a subject's head, the method comprising: positioning the subject's head in a fixture; determining the position of the subject's pupils with respect to the fixture; scanning the subject's head with a laser while positioned in the fixture in order to obtain a 3-D model of the subject's head; providing a helmet liner having an outer surface which is profiled to position it inside a helmet shell; using the 3-D model to provide the helmet liner with an inner surface which conforms to the subject's head and is positioned with respect to the outer surface so that the outer surface will have a predetermined position with respect to the subject's pupils; and fitting the helmet liner in the helmet shell to form a helmet, whereby, the helmet shell may be fitted with pre-positioned optics which are properly positioned with respect to the subject's pupils when the helmet is worn on the subject's head.