Shin Pads

Similarly to the scoliosis example, this case study demonstrates ISF's use for per-user customisation as the process can produce inexpensive moulds with short lead times.

Background: custom-fitted sports equipment or moulds

Shin pads for contact sports such as football and rugby rarely fit perfectly. Often, they dig in because they are too small or slide around because they are too big.

ISF could act as a cheap alternative to additive manufacturing by producing shin pads perfectly fitted to an individual. Similarly, custom-fitted geometries could be created for other segments of the sportswear industry, including knee pads, elbow pads and wrist guards.

A completed ISF workpiece could either be used in combination with other padding materials as a final product, or as a custom mould for conventionally manufactured plastic equipment.

ISF Steps

  1. A 3D scan of the wearer is taken and imported into CAD software. ISF geometry is modelled to fit the wearer.

  2. The geometry is adapted to be manufactured using ISF.

  3. A toolpath is generated to be used by a CNC machine.

  4. The part is formed.

  5. The part can be used directly, or:

  6. The part can be used as a mould.

Benefits

  • ISF would allow equipment manufacturers to improve the scope of per-customer customisation services.

  • By using an inexpensive metal sheet to produce each mould, costs, wastage may not be drastically affected.

Viability

  • It may be logistically complex to integrate appropriate scanning technology and employee training into sportswear stores.

  • As customisation for consumer goods has not been extensively tested, it may be difficult to attract early interest.