Engineering behind 3D printing sports equipment
The first step of 3D printing starts with creating the digital model. For this, the most commonly used software is CAD or computer-aided design, which allows the 3D rendering of a physical object.
Once the model is ready, a 3D printing method is chosen to bring the object to life. Several methods are available on the market, and manufacturers consider different criteria before settling on one.
SLS: Selective laser sintering
A laser is used in this technique to create solid structures from powdered material. Typically, the powdered material utilized is nylon or other types of polymers.
With its higher precision, SLS can produce more detailed and intricate designs. One more advantage of SLS is that the unmelted powder provides support to the printed object, allowing for the omission of additional support structures.
DMLS: Direct metal laser sintering
DMLS is a method similar to SLS but is specifically used for metal parts. Consequently, it shares all the advantages that SLS offers.
The method is compatible with a variety of metals, including stainless steel, aluminum, 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 well-known for generating high-resolution components with smooth finishes, which are suitable for specific applications, including rigid, flexible, and bio-compatible choices.
SLA continues to be popular today because of its precision and versatility.
Wilson’s innovation
In the case of the Airless Basketball, Wilson has not disclosed the exact method and material used to create it.
Walker briefly touched upon the process of creating the ball, saying, “General Lattice turned Wilson’s concept into a CAD file, EOS selected and refined materials for 3D printing, and DyeMansion added color and finishing touches, while SNL Creative scaled up production.”
The ball’s innovation comes from substituting air pressure with a 3D-printed polymer lattice. The air in standard basketballs escapes as time goes on, influencing the ball’s bounce.
Wilson’s basketball replaces air pressure with elastic polymers, including rubber, silicone, and polyurethane, to create the 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 lattice structure deforms. When the structure reverts to its original shape, it releases energy much like a spring, enabling the ball to bounce back.
Other sports manufacturers are exploring the possibilities of customizable 3D-printed equipment.
The power of customization
One of the appealing aspects of 3D-printed equipment is that it can be tailored to the athlete.
“By streamlining the production process, 3D printing enables the development of highly personalized sports equipment that better fits and enhances athlete performance,” explained Walker.
While Wilson’s Airless Basketball doesn’t showcase this, there are several other notable sports equipment where this customization is evident.
Bauer
Bauer is an equipment manufacturer specializing in ice hockey gear. They offer customizable gear in the form of helmets.
“Bauer has an SLS helmet in the NHL and available at hockey retailers,” said Walker. SLS is ideal for producing intricate parts, which are required for hockey helmets.
The product—MyBAUER Re-Akt—is fully customizable and built from an athlete’s 3D head scan. This level of customization means that there is high comfort, less wasted space, and better fit.
As Walker mentioned, these are used by several players in the NHL.
Cobra
Golf equipment manufacturer Cobra has also entered the 3D printing market, offering custom golf clubs known as LIMIT3D. These are commercially available and are made using DMLS.
During the 2024 American Express Tournament, professional golfer Rickie Fowler presented the RF Wedge, a prototype golf club he co-designed with Cobra.
Cobra has also developed 3D-printed putters using carbon fiber, which is lightweight, allowing for better customization. One of the unique features that Cobra added to their second generation of 3D-printed putters 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, a crucial requirement for golf clubs.
Walker added, “Golfers are probably some of the craziest athletes about their gear. Most recently, Bryson DeChambeau won the U.S. Open with 3D printed iron prototypes from start-up, Avoda.”
Nike, Adidas, and others
3D-printed customizable shoes are probably the most common equipment you may have heard of when discussing 3D-printed sports gear. Similar to 3D-printed helmets, the process involves a 3D scan of the athlete’s foot to personalize the shoe.
Nike even co-designed a shoe with Olympian Allyson Felix. They use SLS technology along with a lightweight material they call Flyknit to produce a form-fitting shoe, with 3D-printed components contributing to reduced weight and better grip.
Challenges and roadblocks
These innovations are capable of pushing athletes and the sports industry forward. However, one question still needs to be addressed.
What are the most significant issues or difficulties that 3D-printed sports gear is encountering at the moment?
Cost and production
“The biggest hurdle to widespread adoption of 3D printing in sports equipment manufacturing is the current cost and production speed compared to traditional manufacturing methods,” mentioned Walker.
Athletes can gain performance advantages from using 3D-printed sports equipment. A 2020 study by Noak and Novak found that 38% of existing research about 3D-printed sports equipment showed better performance than traditionally manufactured ones across 12 sports.
However, they also found that 31% noted no difference. This may point to the core problem.
“At the moment, the technology is best suited for professional athletes, elite amateurs, and dedicated enthusiasts. Given the significant performance advantages offered by 3D printing, it’s likely that less skilled or demanding athletes would not fully appreciate the performance benefits,” explained Walker.
Produced in limited batches or on a custom-order basis, these equipment pose challenges for large-scale manufacturing. This also means it is not economically feasible for the industry, driving up the prices of the equipment.
For instance, Wilson’s Airless Basketball hit the market at $2,500, making it a rather pricey option!
Regulations
In addition to the cost and production, regulatory hurdles are also potential roadblocks for this industry.
“Internal performance standards set by sports equipment manufacturers and governing bodies such as the USGA (United States Golf Association) require data to ensure that the products don’t cheat or cross the performance line of providing an unfair advantage,” explained Walker.
In addition, sports equipment must pass safety checks for things like helmets. The challenge here is that since each product is unique, each one requires individual testing.
“For example, Bauer had to develop a new testing methodology for snowflakes when no two helmets are the exact same. Traditionally, each individual helmet size is tested,” added Walker.
Looking at the positives
Environmental benefits
It is no secret that traditional manufacturing involves large-scale production, which leads to waste, overproduction, and higher energy consumption.
3D printing, by contrast, would have a lower environmental impact because it relies on small-scale production.
Currently, there is no specific research providing precise figures for the environmental impact of 3D-printed sports equipment. However, a 2023 analysis by Yale University students found that 3D-printed shoes result in 48% lower carbon emissions and consume 99% less water compared to conventional manufacturing methods.
“For polymer-based sports equipment, 3D printing offers a significant environmental advantage by utilizing a wide range of non-petroleum materials. That alone reduces the carbon footprint compared to traditional manufacturing processes,” added Walker.
Value of prototyping
Walker mentioned that prototyping is still the most valuable application of 3D printing in the sports industry. It gives manufacturers and designers an opportunity to see and test their designs before they are brought to life.
“The creation of the Wilson basketball exemplifies this efficiency. During the development phase, EOS was building a ball, DyeMansion was smoothing it, and Wilson was physically testing the 3D-printed ball design against an NBA ball spec every 1-2 days. That is incredible,” explained Walker.
Rapid prototyping, which allows for the creation of a model quickly, accelerates innovation. It also reduces waste and allows for real-world testing of the product to ensure that all performance and safety requirements are met.
What does the future look like?
3D-printed sports manufacturing is still very new, facing roadblocks in the form of cost, production, and regulations. Additionally, it may only be geared towards a very small population.
Despite this, Walker mentions that helmets and golf clubs would be the top applications, predicting they will reach all high-end consumers within the next decade.
Researchers have also been exploring more nuanced applications of 3D printing in sports.
A team of researchers led by Lawrence Smith developed advanced padding using 3D printing to improve impact absorption. The team altered the internal structure of the foams in shoes to enhance their capacity to endure impact forces.
They tested their newly developed foam and discovered that their designs offer an average of 10% higher energy efficiency compared to traditional cushioning materials.
Possible innovations in this field are endless, as showcased by this research. From material and design to optimizing performance and comfort, the field of 3D-printed sports equipment holds a lot of anticipation.
Whether or not it is meant for large-scale consumption still remains unclear.
