3D head scanning for custom helmets: how does it work?

• In short

  Custom-made helmets are gradually replacing standard sizes (XS, S, M, L) across the helmet industry — cycling, skiing, motorcycling, riding, or professional protective equipment. 3D head scanning for custom helmets lets manufacturers capture a customer’s head shape directly from a smartphone, in-store or remotely. Using MyFit mobile photogrammetry, the resulting 3D model is immediately usable to fit a helmet or recommend the right size, with no specialized hardware.

What types of helmets can be custom-made?

Custom-fit helmets apply to many sports and to jobs that require specific head protection.

For sports

Several sports require proper head protection, with manufacturers increasingly offering custom-fit options — better comfort, but above all better safety:

• custom cycling helmets, for road or mountain biking;
• custom ski helmets;
• custom motorcycle helmets;
• riding helmets.

For professional use

Some professionals need to wear a helmet all day, where a poor fit to the skull shape quickly becomes a problem.

In aviation, pilots need helmets that often integrate communication systems, where an optimal fit is essential in a demanding environment. In construction, personal protective equipment (PPE) needs to be fitted to each worker’s morphology to effectively fulfill its protective role. In the military, a custom-made helmet ensures a precise fit while meeting the specific requirements of each mission.

Why choose a custom helmet over a standard size?

Manufacturing custom helmets offers several benefits, for both manufacturers and customers:

• Broader product range: offering custom helmets makes it possible to meet the specific needs of a wider range of customers, from casual athletes to demanding professionals.
• Fewer returns: a properly fitted helmet reduces the risk of returns linked to size or comfort, with a direct impact on customer satisfaction and loyalty.
• Brand image: offering a personalization experience strengthens brand image, with a 3D scanning solution that can be deployed white-label.

How does 3D head scanning for custom helmets work?

• Step 1: getting ready

  Before starting, the face needs to be clear for optimal capture. A cap or flattened hair that closely follows the shape of the head ensures a faithful capture of the skull shape.

• Step 2: staying still

  During the scan, staying completely still is essential to avoid any distortion in the resulting 3D model.

• Step 3: making the right movement

  The scanning motion needs to be methodical: moving around the head at a constant distance, while also passing over the top to capture every angle.

Once the scan is complete, the 3D head model is available within moments, directly on the smartphone or through the associated web platform, in .stl or .obj format. This platform integrates with existing digital processes through standard connectors (APIs and webhooks).

Standard sizing or custom-fit: what’s the difference for helmets?

Criteria	Standard size (XS, S, M, L…)	Custom-fit helmet (MyFit 3D scan)
Fit	Approximate, by size bracket	Adapted to individual morphology
Comfort	Varies by head shape	Optimized for each head
Safety	Standard	Better hold, better positioning
Measurement equipment	None (declared size)	Smartphone, no accessory
Remote capability	Not applicable	Possible
Return rate	Higher in case of poor fit	Reduced thanks to a faithful 3D model

This same 3D head scanning approach applies to other custom products, such as custom-made glasses.

FAQ