How 3D Scanning is Used for Custom Sportswear

In the world of competitive sports, winning is often measured in milliseconds. Athletes and sports equipment manufacturers are constantly looking for that competitive edge that will put them in the winner’s circle. 3D scanning is fast becoming a go-to tool for companies looking to cut the product development cycle and create custom sportswear that gives athletes the edge they are looking for.

Custom Children’s Riding Helmet

3D scanning is used in a myriad of ways, not only to scan different products, but also the human body in order to design custom sportswear and many sports-specific products. From custom-made shoes, to helmets, mouth guards and prosthetics, you probably own one of these products.

Cerebra Innovation Centre, a UK charity focused on helping children with brain-related neurological conditions, needed to create custom riding helmets using 3D scanning and printing. The lightweight Artec Eva was used to scan quickly, requiring children to hold still for less than one minute.

Artec Eva during scanning

After scanning and exporting to CAD, a two-part model is created. The inner polystyrene protective layer is exported for CNC machining and the shell model is used to create a 3D printed mold. Once the inner surface of the mould is made smooth, layers of fibreglass and Kevlar are laid up using epoxy resin to make an extremely strong outer shell.

Commercially available helmet (left) vs Artec Eva scanned & 3D printed helmet (right)

Create Fastest Custom Skinsuits

3D scanning can be used to help many Olympic athletes and pro sports teams gain a competitive edge. It can be used to determine the best aerodynamics and create custom sportswear to help gain more speed and cut precious time in sports such as cycling, luge, bobsled or rowing.

Vorteq, the sports-focused R&D company chose Artec Leo for creating custom, perfectly-fitting aerodynamic skinsuits for cyclists of all levels.

Artec Leo is a revolutionary handheld 3D scanner with a built-in touchscreen and up to 80 fps capture rate. It excels at capturing medium-sized objects such as people in mere minutes.

Artec Leo 3D scanner with Artec Studio software displaying scan of rider

3D Print Mannequins

Vorteq also use Artec Leo to create scans for 3D printing anatomically-precise mannequins of athletes.

The Artec Leo quickly and accurately capture the precise anatomy of athletes. This digital data is then used to 3D print anatomically-correct mannequins, enabling the remote creation and aerodynamic optimization of custom skinsuits for athletes worldwide.

3D scanned and printed mannequin components ready for assembly and wind tunnel use

The Leo’s handheld, cable-free design enables rapid scanning at any location, such as training camps or competitions, supporting fast turnaround for urgent athlete needs. Then then 3D-printed mannequins eliminate the “wiggle factor” of live athletes, ensuring that only fabric and design changes affect wind tunnel results, leading to more reliable aerodynamic gains.

Conclusion

In conclusion, 3D scanning is changing the sportswear industry by enabling customized performance gear. From capturing an athlete’s body dimensions to creating custom apparel, footwear, and equipment, the technology ensures comfort, support, and mobility. 3D scanning not only enhances athletic performance but also sets a standard for how sportswear is being designed and manufactured.