Toolkit3D Helps Make VICIS ZERO2 MATRIX the NFL's Top-Rated Helmet
Certor Sports and VICIS used Toolkit3D's scan-to-fit design engine to turn player head scans into personalized 3D-printed helmet padding configurations.
From Adjustable Pads to Personalized Protection
VICIS already offered custom fit through its DTLA Pod Fit System, where players could modify interchangeable pads across six helmet zones. The drawback was time: each zone was adjusted, tested, and retested manually.
VICIS set out to develop a more accurate fit and a more modern manufacturing path. Working with Carbon, the team developed 3D-printed lattice structures to replace standard pods with durable, impact-absorbing MATRIX pads.
Perfecting the Fit with Toolkit3D
Toolkit3D built the VICIS Scanning App so teams could create player databases, capture 3D head scans, initiate the automated scan-to-fit process, and retrieve or modify custom fit configurations.
Teams capture a 3D head scan and manage player records in the VICIS Scanning App.
Toolkit3D repairs and rectifies the scan, removing noise like hair or shoulders.
Constraint Template Morphing positions the helmet and fits each MATRIX pod to the player's head.
Players can receive either personalized MATRIX pads or best-fit standard DTLA pad suggestions.
What the Design Engine Automated
Inside Toolkit3D's scan-to-fit design engine, each MATRIX pod is fit to the player's head while accounting for comfort, structural requirements, resin drainage, printability, and how the pods connect back into the helmet shell.
Scan Landmarking
The engine detects more than 3,000 anatomical and non-anatomical landmarks to build an accurate fitting reference.
Scan Reconstruction
Raw scans are repaired, cleaned, and rectified before fitting, including removing artifacts such as hair or shoulders.
Configuration Management
Teams can retrieve, modify, and manage player-specific MATRIX or DTLA pad configurations from the same workflow.
Top Rated for Safety by the NFL and NFLPA
In the NFL and NFLPA's 2023 laboratory helmet testing, the VICIS ZERO2-R MATRIX ID TRENCH took the number one spot. Overall, VICIS held the top five spots, with three helmets using 3D-printed MATRIX pads.
"We're excited to continue exploring the possibilities of intelligent fitting and automation with the fantastic team at Toolkit3D."
Outcomes
VICIS replaced zone-by-zone manual fitting with scan-driven fit recommendations.
Toolkit3D connected player data, scan capture, automated fitting, and configuration management.
Each MATRIX pod can be fit for comfort while respecting printability and helmet constraints.
The workflow supports a path toward automated print-ready files routed directly to manufacturing.
Ready to bring scan-to-fit automation to your product?
See how Toolkit3D can help turn scan data, design automation, and manufacturing constraints into a personalized product workflow.
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