Becoming a champion also means protecting yourself. From the NFL to the NHL, in a sports context where athlete safety is a central concern, technological advances are now turning to innovative solutions to protect players on the field. 3D printing is emerging as a promising option for revolutionizing the design of American football helmets, which is where company Vicis has made its play. The goal: to reduce the risks of head injury associated with the sport and keep players in the game.
Vicis brand helmets, which have consistently achieved excellent results in NFL tests over the years, have taken another step forward thanks to cutting-edge additive manufacturing technology. Case in point, the helmet is being worn by more and more players across the NFL, such as 49ers defensive lineman Nick Bosa and a string of high-profile QBs including Tua Tagovailoa, Derek Carr and Patrick Mahomes. Although its outward appearance seems ordinary, the inside of this helmet conceals 3D-printed pads, specifically designed to adapt to the shape of the head.
The Zero2-R Matrix ID Trench helmet from Vicis sets itself apart by incorporating customized padding manufactured using 3D printing, replacing the traditional foam padding that lines most football helmets. According to the results of laboratory tests, the use of this new technology can reduce the force of impact by up to 7% when a head comes into contact with the ground. The helmet’s padding consists of a series of lattice structures, carefully designed to combine lightness with the ability to absorb impact more effectively. These structures can be adapted not only to the shape of the player’s head but also to take into account his position on the pitch and the types of impact to which he is most likely to be exposed. Vicis improves its production by using the Carbon L1 3D printer, capable of producing padding for two helmets in a single print. This reduces printing time from eight down to just two hours per part, resulting in lower manufacturing costs. To guarantee a customized fit for each player, Vicis also relies on a 3D scanner called the Structure Sensor Pro.
