Within the sports industry, 3D printed helmet designs are gaining traction. These new, additively manufactured designs are an innovative approach to a product that’s had little change in decades. You can now find 3D printed helmets for sports including wrestling, football, and soccer.
Contact sports increase the likelihood of impact between athletes and can lead to higher rates of concussion. 3D printed helmets help disperse the force of these impacts and offer an added layer of protection for athletes. Though no sports helmet can completely prevent concussions, the design of 3D printed helmets can help lessen the risk.
3D Printed Lattice Design
One company seeing an uptick in additive manufacturing orders for protective sports equipment is ABCorp, whose 3D printing division offers a wide range of services. Neil Glazebrook, the company’s VP of 3D Solutions, says it produces several different kinds of sports equipment, both customized and low-volume production options.
“There’s a particular focus on improved head protection in sports right now because of high concussion rates,” says Glazebrook. “We produce wrestling helmets that give athletes full head protection and are a huge improvement over the old design.”
Studies show that brain injuries from contact sports are more often a result of the numerous smaller hits that athletes take during a game or match, rather than a massive head-on collision. The design of 3D printed helmets can help reduce the effect of these cumulative impacts.
This is due to the lattice design inside the 3D printed helmets, which offers more protection to wearers. These helmets are made of TPU, a flexible material that enables 3D printers to create such designs.
“By using a lattice design, 3D printed helmets change the durometer of the impact area,” Glazebrook explains. “In conjunction with the TPU material, this design disperses the impact across the entire helmet, which reduces the chance of concussion.”
The Potential of 3D Printed Sports Equipment
3D printed helmets have proven to offer better protection compared to their traditionally manufactured counterparts, but this benefit is not the only reason manufacturers are incorporating more 3D printing technologies into sports equipment production.
On the production side, manufacturers can reduce labor by using additive manufacturing rather than traditional manufacturing, because they can create products in one piece rather than having to assemble multiple pieces. This also allows companies to follow an on-demand production model, thus reducing stock.
From a market standpoint, consumers are attracted to the style of 3D printed products. “For example, with helmets, the 3D printed design is smaller and sleeker versus traditionally manufactured helmets,” says Glazebrook. “So now athletes don’t have to wear this giant, cumbersome helmet. 3D printed helmet designs are more streamlined, and the product performs just as well, if not better.”
3D printed helmets can also grow along with younger athletes. For example, ABCorp is working on creating a wrestling helmet that can adjust two or three sizes.
“The beauty of 3D printing is you’re not limited in design, and that’s helping create sports equipment that not only offers better protection, but is also more accessible for all athletes,” says Glazebrook.
The Future of 3D Printed Helmets
Though 3D printed sports equipment has a long way to go to become standard in the industry, the market is shifting toward greater adoption of additive manufacturing. The next few years will be crucial to how the industry progresses.
“Progress is going to depend on two things,” explains Glazebrook. “The first is how fast manufacturers can make industrial 3D printing cost-effective and scalable. And the second is the change in people’s buying patterns. When you’re choosing between two helmets, and one offers more concussion protection for your child, the majority will choose that one.”
Glazebrook says the market is there for 3D printed helmets and other sports equipment; manufacturers just need to meet the demand. One thing Glazebrook views as a barrier to wider adoption is the cost of 3D printing equipment. If a company spends $500,000 on a 3D printer, the return on investment (ROI) could take years. But if the company could spend just $100,000 on a 3D printer that has the same capabilities, it would have a much better ROI.
“At that price point, manufacturers will be more likely to adopt 3D printing technologies, and be able to scale much quicker, because it’s not such a massive capital expenditure,” says Glazebrook. “That’s what 3D printer manufacturers should strive for, and it’s the direction the industry needs to be heading.”
For 3D printed helmets and other 3D printed sports equipment, the market is still growing. 3D printed equipment is gaining popularity in professional and collegiate sports, but it’s going to take some time before these products are widely adopted by athletes at all levels. Glazebrook estimates that within the next five years more 3D printed sports equipment will be available, especially protective equipment.
Connect with Neil at RAPID + TCT, North America’s largest additive manufacturing and industrial 3D printing event, hosted in Detroit from April 8-10, 2025. Learn more about ABCorp’s 3D printing capabilities at abcorp-3d.com. Don’t forget to register for RAPID + TCT 2025 to secure your spot today!
Bio:
Neil Glazebrook, VP of 3D Solutions at ABCorp
ABCorp is a secure on-demand manufacturer of 3D printing parts from low to high-volume production using the HP MJF solutions and automated robotics and inspection technology. With over 26 years in manufacturing, Neil has previously worked as a director of Sales and Operations, Mold & Coating Manager, Capital Additive Sales, HP Product Manager, and CNC Programmer in the job shops and injection molding industry. Neil holds a BS in Business and Law from Curry College of Milton, MA, and he currently resides in central Massachusetts. His goal is to bring manufacturing closer to ABCorp’s customers with enterprise-scale manufacturing on-demand using the latest technology in 3D printing, robotics, and inspection.