Revolutionising Sports Gear: How Additive Manufacturing is Shaping the Future of Performance

Sports equipment has come a long way. But what if we could take it even further?

Welcome back to our short series of Innovation in Additive Manufacturing where we highlight some incredible products and engineering in the additive industry. 

Additive manufacturing is unlocking a new era of innovation, allowing for the creation of customised, high-performance gear that's tailored to the specific needs of athletes.

Hockey equipment manufacturer Bauer Hockey has teamed up with EOS to revolutionise helmet design. By incorporating EOS' patented Digital Foam technology, Bauer has created the REAKT helmet, a personalised piece of equipment that offers superior protection and comfort.

Digital Foam allows Bauer to design helmet liner inserts with intricate lattice structures, reducing weight and improving breathability. The process begins with a 3D scan of a player's head, which is then used to create a digital file. This file is then printed using EOS Selective Laser Sintering technology, resulting in a custom-fit helmet liner.

The REAKT helmet has already gained popularity among NHL players, with stars like Cale Makar and Jack Eichel wearing it during the 2022 season. Bauer has made the helmet available to consumers through its MyBauer program, offering personalised protection to athletes of all levels.

The success of the Bauer REAKT helmet demonstrates the potential of additive manufacturing to revolutionise the sports equipment industry. Beyond helmets, 3D printing can be applied to a wide range of sports equipment, including:

• Footwear: Custom-fit insoles and cleats can be produced using 3D printing, improving performance and comfort.
• Prosthetics: Athletes with disabilities can benefit from lightweight, durable, and customised prosthetic limbs made with additive manufacturing.
• Equipment Components: 3D printing can be used to create complex components for sports equipment, such as grips, handles, and frames.
• Personalised Gear: Custom-fit sports gear, tailored to individual athletes' needs, can be produced using 3D printing, enhancing performance and reducing the risk of injury.

As 3D printing technology continues to evolve, we can expect to see even more innovative applications in the world of sports equipment, pushing the boundaries of what is possible.