Slowly but surely, 3D printing is becoming less of a foreign, futuristic term and more of a modern and innovative approach to engineering and design. The world has had a taste of the amazing potential 3D printing has to offer through the creation of 3D printed prosthetic limbs, 3D printed clothing and even 3D printed food! As 3D printing becomes a more popular practice, it also becomes a more viable one. The world will start to see 3D printing more and more in their everyday lives. Right now, the activewear industry is slowly but rapidly taking advantage of 3D printing because of its precision, high level of customization and sustainability consciousness. Nike, Inc has recently shown the most innovation and ambition when it comes to using 3D printing in their products, making them one of the first companies in the activewear industry to take that first step towards incorporating 3D printing.

3D printing is quickly changing the activewear industry, particularly its sneaker game. It benefits the shoe industry by providing customers with better customization, better fit and lighter weight flexibility. Companies such as Nike, Feetz and United Nude have utilized 3D printing to provide their customers with these benefits. Take Nike for example; two years ago in 2013 they redefined the 3D game in activewear by introducing new 3D printing plate construction built for linear speed in their Nike Vapor Laser Talon cleat (pictured below).

This cleat project was the impetus for the new way Nike designs and manufactures their footwear and helped to influence the Nike Vapor Carbon Cleat (thought it did incorporate 3D printing) that was designed only less than a year after the Vapor Laser. However, in 2014 Nike again reemerged with a third 3D printed cleat called the Nike Vapor HyperAgility Cleat (pictured below). This shoe demonstrates the use of SLS (selective laser sintering) plate construction and was born from Nike’s “Shuttle Project”. SLS is a 3D printing technology that uses high powered lasers to fuse small particles of materials (such as plastic) into a three dimensional shape. Normally, SLS is used for prototyping but through careful materials selection, Nike was able to use the technology to produce fully functional, final products.

In addition to linear speed, football players must also be agile and quick on the field. To keep these skills in check, athletics practice the “shuttle” or “5-10-5” drill in order to assess their agility and speed. The Vapor HyperAgility provides optimal traction on turf, reduces deceleration time and increases traction confidence, all of which are critical when an athletic “cuts” or wants to change directions quickly. The video below demonstrates these benefits of the HyperAgility cleat while shuttling.

https://www.youtube.com/watch?v=F1AP167Ig8k

Specifically what is 3D printed in the HyperAgility Cleat is its unique tri-star shape plate design on the sole of the shoe. This plate is designed to be hand laced with the upper part of the shoe using Nike Flywire cables. The mid-cut design also features a compression collar that provides a close fit as well as protection from the studs.

In addition to 3D printed cleats, Nike was also successful in printing shin guards and duffel bag called the Rebento Duffel, which just so happens to be the world’s first 3D printed performance sports bag (pictured below). Complemented by premium leather, the bag, first introduced in 2014, features a 3D printed undercarriage that provides support and visual color contrast to the bag. Rebento is Portuguese for “explode” which is both appropriate for Nike’s ambition and passion towards 3D printing in their designs as well as the grand presence their 3D printed products make when displayed. Reserved for only the most elite athletics at the moment, only three Rebento bags have been seen carried by Neymar Jr., Wayne Rooney and Cristiano Ronaldo.

Lastly come the Mercurial Flylite shin guard which rounds out the beginnings of Nike’s 3D printed equipment which became available July 2014 (pictured below). The combination of materials and innovative design provides the wearer with complete protection and a barely-there feeling. The technology allowed Nike to develop a new webbed shock absorbent system to replace traditional foam protection in shin guards. This system gram per gram provides a more consistent impact absorption hit after hit than foam. The use of 3D printing in these shin guards also decreases the amount of material used to make them, reducing excess material.

3D printing technology has revolutionized the way footwear designers think about design. Not only does this type of technology reduce waste, it also provides wearers with a custom fit that in turn provides them with best arch and overall foot support. For people who experience issues with poor fit, 3D printing provides the best orthopedic solution. Although Nike currently leads the 3D printed shoe game, other companies such as Feetz and United Nude are also using the same technology in footwear. It won’t be long before Nike has some major competition in the field!