“I talked with some friends of mine who also play fùtbol,” said Schmied. “They felt the same. The guard we wanted still had to be invented.”
Already involved in Bernstein Innovation with his father, now a top 3D printing service bureau based in Linz, Austria, they began a new project with Zweikampf—as well as embarking on a challenging mission—to create a three-part shin guard system which eliminates issues caused by the all-too-common ill fit.
Bernstein Innovations’ specialty is in the design and production of SLS 3D-printed components for a range of clients in the industry, offering everything from examples like this niche sports equipment to medical products. We’ve been following the innovators in sports equipment since their Zweikampf Shin Guards launched on Kickstarter in hopes of raising €50,000 ($56,418 USD) by May 17th. Now, a case study has also been released regarding the protective gear and how these innovators relied on the 3D Systems DuraForm PA materials and SLS 3D printer to develop their first consumer product.
The custom system offers three layers:
- The 3D printed shell
- A custom layer
- A comfort layer
Not only are the guards ultra lightweight, but their texture, with a high friction coating, stops the age-old issue of ‘sock slippage.’ Using a 3D Systems sPro 140 SLS 3D printer, Bernstein Innovation produced the shin protection system, as well as employing it on a daily basis in their work for providing parts and prototypes to clients.
“SLS allows us to create final products that meet our demands, and is compatible with a broad range of materials that suit our, and our clients’, different needs,” said Stefan Niedermair, Chief Technology Information Officer, Bernstein Innovation.
Currently, they are able to use the technology of the 3DS printer to output 300 – 350 shin guards per build using 3D Systems DuraForm PA material. Fully automated powder handling encourages the maximum level of efficiency with continuous operation possible at their site where the guards are fabricated, dusted off to removed excess powder, and then according to the case study, ‘recycled back into the printer, and sand blasted.’ After that, the team used ‘infiltration and coating processes’ to get the desired look.
“We set out to make a shin guard that fits the body better than any other model on the market,” said Viktoria Reidl, Product Development, Bernstein Innovation. “We scanned numerous players and developed sizes based on real world data to provide an anatomical fit.”
While the Bernstein team has begun with a more basic system as they evaluate what the market interest and demand will be, the ultimate goal for the company is a professional system which they envision as being fully customized, offering players gear that is completely specific to them via 3D scanning. Currently players will find the shin guards available in three sizes with options for soft, hard, or in between—depending on comfort requirements as well as what type of impact they expect to experience during the game.
As we often point out, the best products in this industry often arise from users who had their own specific need—such as Schmied’s painful shin condition—which motivated them to create a high-quality product that resonates with others as well. You can find out more about Bernstein Innovation here, as well as checking out their Kickstarter campaign. Below too is a video which explains more about their evolution as a company and why they decided to make such a product.
According to 3D Systems, Duraform PA material is also suitable for:
- Prototypes that require good durability and strength
- Low to mid volume direct manufacturing of end-use parts
- Medical parts that require USP Class VI compliance or must be sterilized
- Complex, thin-walled ducts
- Aircraft and motorsports parts
- Enclosures and housings
- Parts with snap-fits and living hinges
- Automotive dashboards, grilles and bumpers
Specifications on the sPro 140 3D printer follow:
Model: sPro 140
Manufacturer: 3D Systems
Build envelope capacity (XYZ): 22 x 22 x 18 in (550 x 550 x 460 mm), 8,500 cu in (139 I)
Powder layout: Precision Counter Rotating Roller
Layer thickness range (typical): Min 0.08 mm (0.003 in); Max 0.15 mm (0.006 in), (0.004 in, 0.1 mm)
Imaging System: ProScan™ Standard, Digital Imaging Systems
Scanning speed: 400 in/s (10 m/s)
Laser power/type: 70 W / CO2
Volume build rate: 185 cu in/hr (3.0 L/hr)
System warranty: One-year warranty, under 3D Systems purchase terms and conditions
Electrical Requirements:
System: 208 V/17 kVA, 50/60 Hz AC 50/60 Hz, 3-phase (System)
Standard Features:
System Control & Part Preparation Software: LS4.4 Sinter/BuildSetUp Software featuring part Add/Delete on-the-fly for flexibility, SinterScan Module for high accuracy and part consistency, and Build Time Estimator.
Other options:
RemoteNotify Software Module: Automatically send emails upon machine status change, including build height, part completion, alarms, etc.
RealMonitor & Graphic Viewer-Advanced Software: Logs laser, heater, and sensor data during build and allows for export to a database for statistical process control.
Discuss this technology and new product in the 3D Printed Shin Guards forum over at 3DPB.com.