Abstract: A customized head protection device comprising: a base plate shaped and dimensioned to shield a cranial defect area of a subject, the base plate comprising an cranial defect outline defining a first parameter around the cranial defect area, and a margin outline defining a second parameter around the first parameter, wherein the area between the first parameter and the second parameter defines an extension region adapted to fit onto a skin portion of the subject when worn. Also provided is a method of manufacturing the head protection device comprising identifying the cranial defect area of the subject, determining the aforementioned cranial defect and margin outlines, generating a 3D model object and 3D printing the device based on the 3D model object.