Application of 3D printing in sports

1、What is 3D printing?

3D printing, also known as additive manufacturing, is a production technology that creates three-dimensional objects according to computer-aided design (CAD) files. It involves several processes that build up one or more materials such as plastic, metal, wax or composite materials layer by layer to form a shape. The process is computer-controlled, making it an economical and accurate way to create objects of almost any geometry and complexity. Today, 3D printing is used in various industries to produce prototypes, tools, fixtures, components and final parts.

2、How does 3D printing work？

The software slices the digital 3D model into hundreds of thin layers and exports them in G-code format. This format is the language that the printer uses to know exactly when and where to deposit material. Each layer corresponds to the exact 2D shape of a section or slice of the object. For example, if you want to 3D print a pyramid, the first layer (the bottom) is a flat square, and the last layer (at the top) is a tiny dot. It is printed layer by layer until the entire object is printed.

3、Impact of 3D printing on the sports industry

1）.How does 3D printing change the sports industry?
3D printing has many advantages in the sports field, including accelerating product design and development, improving design flexibility, speeding up product modification and improvement, manufacturing lighter and stronger equipment, improving aerodynamics, and enhancing customization options. In the sports world, subtle differences determine victory or defeat, and improvements in athletes’ reaction speed and injury healing speed can bring competitive advantages. Weight is crucial to athletes’ performance. 3D printing can design and manufacture products that are lighter and as strong as traditional manufacturing methods. It also provides greater design freedom and can be combined with laser scanning technology to achieve high customization of products. At present, 3D printing is becoming more and more affordable and popular in the sports field. Many sports manufacturers are using this technology, and the scope of application is constantly expanding. There will be more innovations in the future.

2）.3D printing helps Paralympic gold medals
Take Emma Wiggs, the world champion disabled kayaker, as an example. She knew that customizing a stronger and lighter paddle would increase her strength. The design of traditional paddles has hardly changed and has not been ergonomically adjusted for disabled athletes, so the Paralympic champion and relevant engineers worked together to develop a solution. The redesigned carbon fiber paddle was designed based on a computer simulation model of Emma’s ergonomics and personal technique, with a handle custom-made to her hand shape, lightweight and 3D-printed from a high-performance polymer. The resulting paddle was significantly improved in several areas, and Emma won gold at the Tokyo 2020 Paralympic Games with it.

4、 Application fields of 3D printing in sports

1）.3D printing customized sports equipment
Including protective equipment (such as helmets, goggles, etc.), sportswear (such as shoes, insoles, etc.), sports equipment (such as bats, clubs, etc.), prostheses, training equipment, etc.
A major advantage of 3D printing in the field of sports is that it can easily produce customized products, which can be customized in a variety of ways, from small changes such as color and logos to complex modifications such as redesigning protective equipment. Ill-fitting equipment will affect sports performance, and the traditional customization process is slow and expensive. The combination of high-definition laser scanning, computer modeling software and 3D printing simplifies and optimizes the process. The unique structure of 3D printed products also helps to improve the comfort and competitiveness of athletes.

2）.Application of 3D printing in sports medicine
Including masks, medical pillows, brackets, plasters, splints, boots, etc.
The application of 3D printing in the field of sports medicine is growing rapidly. Athletes need to recover as soon as possible after injury. 3D printing provides an innovative way to speed up recovery and reconstruct fractures, and its medical products can be quickly customized to achieve the best fit and support for recovery.

3）.3D printing in motorsports
Including decorative parts (such as dashboards, seat frames, etc.) and mechanical parts (such as mounting brackets, suspension wishbones, etc.).
In motorsports, speed and weight are crucial. 3D printing has long been used to make early prototypes that can be tested in wind tunnels. Now it is also increasingly used to produce small batches of final parts, and in some cases the cost is much lower than traditional methods. This is an important consideration in sports with spending caps.

4）.On-demand 3D printing
The ability to manufacture parts on demand has promoted the application of 3D printing in the sports field. Incorporating production processes in-house can better control the process and shorten the time from design to manufacturing.
Many sports teams compete far away from their headquarters and have difficulty obtaining spare parts. The speed, flexibility and efficiency of 3D printing enable them to manufacture parts economically and efficiently when and where they are needed. Digital CAD files can also optimize inventory.

5、Limitations of 3D Printing in Sports

1）.Not suitable for mass production
3D printing may be faster and more efficient than traditional methods when producing single pieces or small batches of items in the sports field, but it still has difficulties in mass production. The number of prints per machine is limited by the size of the machine and the object, so for many products that can benefit from mass customization, 3D printing may not be the fastest or most cost-effective technology.

2）.Regulatory standards
3D printing in the sports field is subject to the same quality checks as other technologies or manufacturing methods. The sports industry is currently in the early stages of adopting 3D printing, and many checks have not yet been completed. The approval process for safety-critical components or protective equipment is particularly strict, and the situation may change as relevant approvals and regulatory standards are introduced.

3）.Unstable quality
3D printers do not always print perfect results. The failure rate is affected by the machine, material and printed object, and sometimes additional manual processing is required to achieve the desired effect. With technological advances and familiarity with the technology, these factors may be reduced, and high-quality printing may require investment in more expensive equipment.

4）.Part size
The size of a 3D printer limits its ability to produce large parts. Although it is possible to connect multiple small parts, this is not always an ideal solution. 3D printer manufacturers are working hard to solve the size limitation problem.

6、Conclusion

In short, 3D printing has shown great potential and value in the field of sports. From changing the development model of the sports industry to helping athletes achieve excellent results, from diverse application fields to its own limitations, 3D printing is gradually becoming an indispensable part of sports.