Method and Apparatus to Generate Measurements for and Manufacture a Conformal Fitting Cap

A method and apparatus to obtain very accurate measurements of the perimeter of a person's head scanning with an optical device; transmitting the scanned data to one or more processors which translate the measurements as precise three-dimensional data wherein an x-y plane is defined as the beginning or lower edge of the conformal cap from which a z-axis extends orthogonally in a upwardly direction towards the crown of a person's head. The three-dimensional data may be further processed to a suitable format for transmission to a transformation tool that moves one or more actuators to create an accurate three-dimensional mold of the person's head, upon which fabric or foam can be applied to create an accurate conformal cap for subsequent uses.