Fit for the modern flight helmet is not just comfort, but includes proper placement of added components (e.g., earcups, helmet-mounted optics, etc.), stability, and even center of gravity location. Many fielded and prototype helmets have been criticized for poor fit, not providing adequate sizes, and compromising safety. In this paper, evidence from studies using new surface digitizing techniques is presented revealing that a large part of the problem is due to the fact that the development of these helmets was based on traditional anthropometry. These findings demonstrate the need for improved methods of specifying, designing, and evaluating helmets. Specifically, for development of equipment which must interface with the human body, there is a need for fit assessment in conjunction with surface scanning to define:​ 1) correct positioning of the human with respect to the equipment;​ 2) proper sizing, and 3) proper size issuing schemes.