3D printing is a technique that transforms digital models into tangible objects by assembling them layer by layer using various materials such as ceramics, metals, and plastics.
Wilson’s Airless Gen1 Basketball.
From a neighborhood in Texas to artificial skin, the versatility of 3D printing is making its presence felt across various fields, including sports. The unveiling of Wilson’s Airless Basketball and Cobra’s Iron Golf Clubs has ushered in an era of innovation in the manufacturing of sports equipment through 3D printing.
Though 3D printing, or additive manufacturing as it is referred to in the industry, is not a recent development, its roots stretch back to the late 1940s, with a formal introduction in the 1980s.
The process of 3D printing involves transforming a digital model into a tangible object, building it layer by layer using various materials such as ceramics, metals, and plastics.
Grounded in a digital design, the resulting object offers great potential for customization. Moreover, it enhances manufacturing efficiency by minimizing waste through on-demand production. These benefits render 3D printing an attractive option for manufacturing sports equipment.
The application of 3D printing in sports equipment is still in its early stages. Athletes now have the opportunity to utilize this technology to acquire custom-designed gear that enhances their performance while reducing the risk of injuries.
This article delves into the transformative impact of 3D printing on the sports industry. Interesting Engineering (IE) had a conversation with Jon Walker, an industry expert serving as the Business Development and Key Accounts Manager at EOS North America, to gather insights about the design process behind Wilson’s Airless Basketball.
Additionally, we will identify obstacles in the industry and discuss the potential future of 3D printing within the realm of sports.
The initial phase of 3D printing involves generating a digital model. The most widely used software for this purpose is CAD, or computer-aided design, which facilitates the three-dimensional visualization of a tangible object.
Once the model is prepared, a 3D printing technique is selected to bring the creation to life. Various methods exist in the market, and manufacturers evaluate multiple factors before making a choice.
SLS: Selective Laser Sintering
This process employs a laser to form solid structures from granular materials. The materials typically used include nylon and other forms of polymers.
Thanks to its superior precision, SLS can produce highly detailed and complex designs. An additional benefit of SLS is that the un-melted powder acts as support for the printed object, eliminating the need for extra support structures.
DMLS: Direct Metal Laser Sintering
DMLS is a technique akin to SLS, designed specifically for creating metal components. As such, it inherits all the benefits associated with SLS.
This method can work with a range of metals, including stainless steel, aluminum, and titanium.
SLA: Stereolithography
SLA, regarded as one of the pioneering methods in 3D printing, employs a laser to solidify liquid resin into solid objects. This technique is renowned for producing high-resolution parts that feature smooth finishes, making it ideal for a range of applications, including rigid, flexible, and bio-compatible materials.
The enduring popularity of SLA is attributed to its accuracy and adaptability.
With respect to the Airless Basketball, Wilson has kept the specifics of the method and materials used for its creation under wraps.
Walker provided some insight into the production process of the ball, stating, “General Lattice transformed Wilson’s idea into a CAD file, EOS curated and enhanced materials for 3D printing, while DyeMansion applied color and finishing touches, and SNL Creative managed the scale-up for production.”
The innovation of the ball arises from the replacement of air pressure with a 3D-printed polymer lattice. Over time, the air in traditional basketballs diminishes, impacting the performance of the ball’s bounce.
Wilson’s basketball features a unique design that employs elastic polymers such as rubber, silicone, and polyurethane to form a lattice or honeycomb structure. These materials are designed to compress and then return to their initial form.
Upon striking the ground, the lattice structure of the Airless Basketball compresses. When it rebounds to its original shape, it releases energy similar to that of a spring, thus allowing the ball to bounce up.
Other manufacturers in the sports industry are also looking into the potential of customizable 3D-printed gear.
One of the attractive features of 3D-printed gear is its ability to be customized for the individual athlete.
“By simplifying the manufacturing process, 3D printing makes it possible to create highly tailored sports equipment that fits better and improves athlete performance,” stated Walker.
Although Wilson’s Airless Basketball does not exemplify this, there are various other prominent sports items where such personalization is clear.
Bauer is a manufacturer known for its specialization in ice hockey equipment, offering gear that can be customized, such as helmets.
“Bauer produces an SLS helmet that’s currently being used in the NHL and can be found at hockey retailers,” stated Walker. SLS technology excels in creating detailed components, which are essential for the design of hockey helmets.
The innovative product—MyBAUER Re-Akt—offers complete customization created from an athlete’s 3D head scan. This extensive customization ensures superior comfort, minimal empty space, and an improved fit.
As Walker pointed out, various NHL players utilize this helmet.
In addition, golf equipment company Cobra has ventured into the realm of 3D printing with its lineup of custom golf clubs known as LIMIT3D. These custom clubs are commercially available and are produced using DMLS technology.
During the 2024 American Express Tournament, professional golfer Rickie Fowler unveiled the RF Wedge, a prototype golf club he collaborated on with Cobra.
Cobra has also introduced 3D-printed putters made from carbon fiber, a material that is lightweight and allows for enhanced customization. Among the innovative elements incorporated into their second generation of 3D-printed putters is the implementation of metal injection molding (MIM).
MIM is a manufacturing technique that merges the adaptability of plastic injection molding with the resilience of metal, an essential characteristic for golf clubs.
Walker stated, “Golfers are often among the most passionate athletes regarding their equipment. Recently, Bryson DeChambeau clinched the U.S. Open title using 3D printed iron prototypes from start-up, Avoda.”
Customizable shoes produced through 3D printing are perhaps the most recognized example when it comes to discussing high-tech sports equipment. Much like 3D-printed helmets, the creation process begins with a 3D scan of the athlete’s foot to ensure a personalized fit.
Nike even collaborated in the design of a shoe with Olympic champion Allyson Felix. Utilizing SLS technology and a unique lightweight material known as Flyknit, they successfully create a shoe that fits like a glove, with 3D-printed elements aiding in weight reduction and improved traction.
These advancements hold the potential to elevate both athletes and the sports sector. Nevertheless, one essential question remains unanswered.
What are the primary challenges currently faced by 3D-printed sports equipment?
“The primary obstacle to the widespread use of 3D printing in the manufacturing of sports equipment is the current cost and production speed when compared to traditional methods,” stated Walker.
Athletes can experience enhanced performance through the use of 3D-printed sports gear. A study from 2020 conducted by Noak and Novak revealed that 38% of the research concerning 3D-printed sports equipment indicated better performance than that of conventionally manufactured items across a range of 12 sports.
However, they also discovered that 31% reported no difference in performance. This could highlight a fundamental issue.
“Currently, this technology is most beneficial for professional athletes, elite amateurs, and passionate hobbyists. Given the notable performance benefits that 3D printing can provide, it’s probable that less skilled or less demanding athletes may not fully realize these advantages,” Walker explained.
Created in small quantities or through custom orders, these devices present challenges for widespread manufacturing. Consequently, this makes them economically unviable for the industry, leading to increased costs for the equipment.
For example, Wilson’s Airless Basketball was launched with a price tag of $2,500, making it quite an expensive choice!
Alongside the high costs and production issues, regulatory challenges are also significant obstacles for this sector.
“Internal performance standards established by sports equipment manufacturers and organizations like the USGA (United States Golf Association) necessitate data to confirm that the products do not cheat or exceed the boundaries of offering an unfair advantage,” Walker elaborated.
Moreover, sports gear must undergo safety evaluations, particularly for items like helmets. The difficulty lies in the fact that each product is distinct, requiring separate testing.
“For instance, Bauer had to create a new testing method for helmets because no two are exactly alike. Typically, testing is done for each individual helmet size,” noted Walker.
It’s widely recognized that conventional manufacturing entails mass production, resulting in waste, excess production, and increased energy use.
In contrast, 3D printing presents a reduced ecological footprint thanks to its reliance on small-scale production.
At present, there is a lack of comprehensive research detailing the exact environmental effects of 3D-printed sports gear. Nonetheless, a 2023 study conducted by students from Yale University revealed that shoes produced through 3D printing lead to 48% lower carbon emissions and utilize 99% less water compared to traditional manufacturing techniques.
“In the realm of polymer-based sports equipment, 3D printing presents a remarkable ecological benefit by employing a diverse array of non-petroleum materials. This aspect alone minimizes the carbon footprint in contrast to conventional manufacturing methods,” stated Walker.
Walker also pointed out that the primary benefit of 3D printing within the sports sector lies in its prototyping capabilities. This technology allows manufacturers and designers to visualize and test their concepts prior to actual production.
“The development of the Wilson basketball showcases this efficiency. Throughout the design phase, EOS was tasked with building the ball while DyeMansion handled the smoothing process, and Wilson was conducting physical tests on the 3D-printed ball design against NBA specifications every 1-2 days. That is truly remarkable,” Walker elaborated.
Rapid prototyping facilitates the swift creation of models, thereby speeding up the innovation process. This method not only minimizes waste but also allows for real-world testing of products to verify that they meet all necessary performance and safety standards.
The field of 3D-printed sports manufacturing is still in its infancy, encountering challenges related to costs, production processes, and regulatory barriers. Moreover, it seems to cater to a very niche audience.
Nevertheless, Walker suggests that helmets and golf clubs are set to be the primary uses of this technology, with predictions indicating they will become accessible to high-end consumers within the next decade.
Researchers are also delving into more specialized uses of 3D printing in the realm of sports.
A group of researchers spearheaded by Lawrence Smith has created innovative padding through 3D printing to enhance impact absorption. By modifying the internal structure of shoe foams, they improved the materials’ ability to withstand impact forces.
Upon testing their new foam, the team found that their designs provide an average of 10% greater energy efficiency compared to conventional cushioning materials.
The potential for innovations in this area is limitless, as demonstrated by their findings. From materials and designs to optimizing both performance and comfort, the world of 3D-printed sports equipment is ripe with possibilities.
However, it remains uncertain whether these advancements will be intended for widespread commercial use.
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Tejasri Gururaj is a dynamic Science Writer and Communicator. With a Master’s degree in Physics, she strives to make scientific knowledge accessible to everyone. In her leisure time, she loves to spend time with her cats, binge-watch TV shows, and recharge with naps.
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