London-based product design and growth consultancy ITERATE and US 3D printer OEM Carbon are collaborating to convey personalized, high-performance sports activities gear to a brand new stage of personalization. By combining ITERATE’s human-centered design method with Carbon’s Digital Gentle Synthesis (DLS) expertise, the partnership allows merchandise tailor-made to particular person athletes whereas supporting extra sustainable, on-demand manufacturing.
Designing for Human Efficiency
Not like conventional 3D printing, Carbon’s course of makes use of mild and oxygen to supply high-resolution elements with versatile lattice buildings that take up influence, adapt to motion, and reply naturally to the physique.
At ITERATE, personalization can be on the coronary heart of each mission. “Each athlete is exclusive – their physique form, motion patterns and efficiency calls for all differ. The problem for designers and engineers is to create merchandise that adapt to these individualities. By way of superior supplies, digital prototyping and additive manufacturing, that problem is now being met,” defined ITERATE.
One instance of this collaboration is the Power Absorbing Arm Guard utilized in cricket, which includes energy-dissipating buildings to guard high-risk areas whereas sustaining a full vary of movement. The mix of ergonomic design and superior supplies demonstrates how AM can ship custom-fit options that improve each security and efficiency.
Past personalization, AM additionally helps extra sustainable manufacturing. Conventional mass manufacturing depends on forecasts, surplus stock, and intensive tooling, producing waste. Carbon and ITERATE’s method allows on-demand manufacturing, usually nearer to the consumer and utilizing extra sustainable supplies, lowering extra manufacturing and lengthening product lifespan.
3D Printing Beneficial properties Momentum in Sports activities
Past cricket, 3D printing is pushing efficiency boundaries throughout varied sports activities sectors. For instance, in biking,Fizik’s One-to-One {custom} saddle program—developed in collaboration with bike-fitting specialists gebioMized and powered by OEM producer Carbon’s 3D printing expertise—secured the Gold Award within the Parts class on the 2025 EUROBIKE Awards. By seamlessly integrating dynamic rider information, automated design, and additive manufacturing, this system exemplifies scalable personalization in efficiency biking.
Elsewhere, Nike, the U.S.-based athletic put on firm, developed a 3D printed sports activities bra utilizing a brand new materials referred to as FlyWeb. The product is Nike’s first software of additive manufacturing in efficiency attire.
FlyWeb is made out of thermoplastic polyurethane (TPU), a delicate and pliable polymer, and is fabricated via 3D printing slightly than conventional knitting or weaving. The fabric varieties a single, seamless layer tailor-made utilizing computational design. Designers adjusted properties reminiscent of stretch, airflow, and help by modulating density throughout completely different zones of the garment. “It took years of re-engineering — not simply the supplies however the design method itself — to make FlyWeb really feel delicate, breathable and exquisite sufficient for attire,” stated Janett Nichol, Nike’s Vice President of Innovation.
Wish to assist form the way forward for AM? Be part of the Professional Committee for our 2025 3DPI Awards, launching later this summer time.
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Picture featured exhibits 3D printed cricket arm guard. Picture through ITERATE.
