3D printed equipment revolutionizes sports, improves athlete performance

One neighbour in texas imitation leather3D printing is used everywhere, including sports. Wilson’s announcement Stuffy Basketball And Cobra’s Iron Golf Clubs It has brought a new wave of innovation to sports manufacturing using 3D printing.

3D printing, or additive manufacturing as it is known in the industry, is certainly not a new technology. appeared in the 1980showever, its concept can be traced back to the late 1940s.

Transforming a digital model into a physical object is accomplished through 3D printing. A variety of materials, including ceramics, metal, and plastic, are used to build the object layer by layer.

The object, which is based on a digital model, offers customization options. It also ensures maximum production efficiency by reducing waste by producing on demand. These advantages 3D printing It is particularly attractive for the manufacture of sports equipment.

But the use of 3D printing in sports equipment is still relatively new. Athletes can now leverage this technology to obtain specialized equipment aimed at optimizing performance and reducing the likelihood of injury.

In this article we explore how 3D printing is changing the sports industry. Interesting Engineering (IE) spoke to industry expert Jon Walker, Business Development and Key Accounts Manager. EOS North AmericaGaining insight into the design of Wilson’s Airless Basketball.

We will also explore bottlenecks and what the future looks like. 3D printing in sports.

The engineering behind 3D printing sports equipment

The first step of 3D printing begins with creating the digital model. The most commonly used software for this is CAD or computer-aided design, which allows the creation of a physical object in 3D.

When the model is ready, 3D printing method It is chosen to give life to the object. Various methods are available on the market and manufacturers consider different criteria before deciding on one.

SLS: Selective laser sintering

a laser This technique is used to create solid structures from powdered material. Typically, the powdered material used is nylon or other types of polymers.

Thanks to its higher sensitivity, SLS can produce more detailed and complex designs. Another advantage of SLS is that the unmelted powder provides support to the printed object, allowing additional support structures to be eliminated.

DMLS: Direct metal laser sintering

DMLS is a method similar to SLS but is used specifically for metal parts. As a result, it shares all the advantages offered by SLS.

The method is compatible with a variety of metals, including: stainless steelaluminum and titanium.

SLA: Stereolithography

SLA is considered one of the original 3D printing methods. It uses a laser to harden or solidify liquid resin to create the object. It is renowned for producing high-definition components with smooth surfaces that are tough, flexible and suitable for specialized applications. biocompatible options.

SLA remains popular today due to its precision and versatility.

Wilson’s innovation

in case Stuffy BasketballWilson did not fully explain the method and materials used to create it.

Briefly touching on the process of creating the ball, Walker said: “General Lattice converted Wilson’s concept into a CAD file, EOS selected and developed materials for 3D printing, DyeMansion added color and finishing touches, and SNL Creative scaled up production.”

The ball’s innovation comes from replacing air pressure with a 3D printed polymer cage. air inside standard basketballs As time passes, it escapes and affects the bounce of the ball.

Wilson basketball replaces air pressure with elastic polymers, including rubber, silicone and polyurethane, to create a lattice or honeycomb design. These materials have the ability to deform and return to their original shape.

When the airless basketball hits the ground, the cage structure is deformed. When the structure returns to its original shape, it releases energy, just like a spring. ball return.

Other sports manufacturers are exploring the possibilities of customizable 3D printed equipment.

The power of personalization

One of the appealing aspects of 3D printed equipment is that it can be customized to the athlete.

“By facilitating the production process, 3D printing “It allows the development of highly personalized sports equipment that better adapts to and enhances the athlete’s performance,” Walker said.

While Wilson’s Airless Basketball doesn’t display this, there are many other notable pieces of sports equipment where this customization is evident.

Bauer

Bauer is an equipment manufacturer specializing in ice hockey equipment. They offer customizable equipment in the form of helmets.

“Bauer has an SLS helmet in the NHL and is available at hockey stores,” Walker said. SLS is ideal for the production of complex parts required for hockey helmets.

Product –MyBAUER Reactivated—fully customizable and created from a 3D head scan of an athlete. This level of customization means increased comfort, less wasted space and better fit.

As Walker noted, these are used by many players in the NHL.

Cobra

Golf equipment manufacturer Cobra has also entered the 3D printing market, offering custom golf clubs. BORDER3D. These are commercially available and are made using DMLS.

During the 2024 American Express Tournament, professional golfer Rickie Fowler presented: RF WedgeThe prototype golf club he designed together with Cobra.

Cobra has also developed 3D printed golf clubs that use lightweight carbon fiber, allowing for better customization. One of the unique features that Cobra added to its second generation of 3D printed golf clubs is the use of metal injection molding (MIM).

MIM is a manufacturing process that combines the versatility of plastic injection molding with the durability of metal, an important requirement for golf clubs.

Walker added: “Golfers are probably some of the wildest athletes around with their equipment. Most recently, Bryson DeChambeau won the US Open with his 3D printed iron prototypes. home, Avoda.”

Nike, Adidas and others

3D printed customizable shoes They are probably the most common equipment you may have heard of when discussing 3D printed sportswear. Similar to 3D printed helmets, the process involves a 3D scan of the athlete’s foot to customize the shoe.

Nike even designed a shoe together Olympian Allyson Felix. They use SLS technology with a material they call lightweight. flyknit Producing a form-fitting shoe with 3D printed components that contribute to weight reduction and better grip.

Challenges and obstacles

These innovations have the capacity to move athletes and the sports industry forward. However, one question still needs to be answered.

What are the most important issues or challenges currently facing 3D printed sports equipment?

Cost and production

“The biggest obstacle to widespread adoption of 3D printing in sporting goods manufacturing is the current cost and production speed compared to traditional manufacturing methods,” Walker said.

Athletes can gain performance benefits by using 3D printed sports equipment. A. 2020 study Noak and Novak found that 38% of existing research on 3D printed sports equipment performed better than conventionally produced ones in 12 sports.

But they also found that 31% noted no difference. This may indicate an underlying problem.

“Currently technology is best suited for this. professional athleteselite amateurs and dedicated enthusiasts. “Given the significant performance benefits offered by 3D printing, it is likely that less skilled or demanding athletes may not fully appreciate the performance benefits,” Walker explained.

Produced in limited numbers or on a special order basis, these equipment pose challenges for large-scale production. This also means that equipment becomes economically unviable for the industry, causing prices to rise.

For example, Wilson’s Stuffed Basketball It hit the market at $2,500, which makes it a pretty expensive option!

Regulations

In addition to cost and production, regulatory barriers are also potential obstacles for this sector.

“Internal performance standards set by sporting equipment manufacturers and governing bodies such as the USGA (United States Golf Association) to betray or exceeding the performance line to gain an unfair advantage,” Walker explained.

Additionally, sports equipment, such as helmets, must pass security checks. The challenge is that because each product is unique, each requires individual testing.

“For example, Bauer had to develop a new testing methodology for snowflakes where no two helmets are exactly alike. Traditionally, every helmet size is tested,” Walker added.

When we look at the positive aspects

Environmental benefits

It’s no secret that traditional manufacturing involves large-scale production, leading to waste, overproduction, and higher energy consumption.

3D printing, in contrast, will have a lower environmental impact because it is based on small-scale production.

There is currently no specific research that provides definitive figures on the environmental impact of 3D printed sports equipment. But, 2023 analysis A study conducted by Yale University students found that 3D printed shoes cause 48% lower carbon emissions and consume 99% less water compared to traditional production methods.

“3D printing for polymer-based sports equipment offers a significant environmental advantage by using a wide range of non-petroleum materials. This alone reduces the carbon footprint compared to traditional manufacturing processes,” Walker added.

The value of prototyping

Prototyping remains the most valuable practice, Walker said. 3D printing in the sports industry. It gives manufacturers and designers the opportunity to see and test their designs before they are implemented.

“The creation of the Wilson basketball is an example of this efficiency. In development, EOS was creating a ball, DyeMansion was tweaking it, and Wilson was physically testing the 3D printed ball design against NBA ball specifications every 1-2 days. It’s incredible,” Walker explained.

Rapid prototyping, which allows the rapid creation of a model, accelerates innovation. It also reduces waste and allows real-world testing of the product to ensure all performance and safety requirements are met.

What does the future look like?

3D printed sportswear production is still very new and faces hurdles such as cost, production and regulations. Additionally, it may only be intended for a very small population.

However, Walker notes that helmets and golf clubs will be the most important applications and predicts that they will reach all high-end consumers within the next decade.

Researchers are also investigating more subtle applications. 3D printing in sports.

A team of researchers Led by Lawrence Smith developed advanced padding that uses 3D printing to increase impact absorption. The team modified the internal structure of the foams in the shoes to increase their ability to withstand impact forces.

They tested their newly developed foam and found that their design offered an average of 10% greater energy efficiency than traditional cushioning materials.

As this research shows, the possible innovations in this field are endless. From materials and design to optimizing performance and comfort, the field of 3D printed sports equipment holds many expectations.

Whether it is intended for large-scale consumption remains unclear.