3D printing has increasingly captured the interest of people from all walks of life, whether for personal hobby projects or professional manufacturing in construction, the automotive industry, aerospace, medicine, and much more. One versatile area that spans both personal and professional use is 3D printing in sports. We have already reported on innovative cycling backpacks, complex Formula 1 technologies, and even 3D-printed sports shoes from Nike and Adidas. Today, however, we want to take a closer look at arguably the most popular sport in the world: soccer, and specifically, the applications of additive manufacturing for soccer equipment.
Stadiums, Merchandising, and More
Before we move on to more obvious applications like clothing and face masks, we want to highlight a few examples from the wider world of soccer. Did you know, for instance, that the stadiums for the controversial World Cup in Qatar were tested using 3D-printed models? Qatar’s desert environment posed a major challenge for engineers and architects, as desert winds and heatwaves are both common and affect spectators as well as professional athletes. According to FIFA, a special wind tunnel was built in Qatar where 1:300 scale models were tested for their aerodynamics. Professor Saud Abdul Aziz Abdu Ghani from Qatar University described the tests as follows: “We can display the temperature for each level, add variables like sweat production and crowd size, then run the simulation and observe the impact on stadium temperatures.”
Stadiums of the 2022 Qatar World Cup (Credit: Qatar’s SCQA)
Beyond highly complex technology tests, 3D printing in soccer is especially popular among hobby crafters. The manufacturing technology makes it easy and affordable to create merchandise. Want to give a friend a detailed figure of their favorite player? No problem. On community-based platforms like Cults or Thingiverse, you can find plenty of models ready to print.
Sample 3D Player Models (Image Credit: Evgeniy Borisenko )
3D-Printed Soccer Gear, from Toe to Head
What was the first thing that came to mind when you thought of 3D printing in soccer? For us, it was the equipment that makes the sport what it is – so today, we are focusing on how additive manufacturing is being used to produce soccer gear. Below, you’ll find a selection of companies and products that currently create 3D-printed items for both professional and amateur players, ranging from soccer shoes and cleat guards to goalkeeper gloves and protective masks.
Soccer Shoes
3D printing soccer shoes is a highly complex process and often fails because of the unique structure of the shoes and their combination of durable materials and studded soles, which are designed to provide better grip on soft ground. There are also strict regulations in professional soccer regarding cleat length and even the materials used in the sole in case a referee considers them dangerous. One major advantage of 3D-printed shoes is the high level of customization, which is a key selling point of the German company IMOTANA. The young startup produces tailor-made soccer shoes, where a scan of the feet ensures a perfect fit. According to the manufacturer, peak performance in any sport is only possible when equipment is used that is precisely tailored to the individual shape of the body.
The business idea comes from CEO and co-founder Benjamin Dorsch, who worked for many years as a development manager at a footwear manufacturer. There, he developed high-end soccer shoes for established brands, including the shoes worn by the German national team during their 2024 World Cup victory. He was always striving for innovations that he could only truly realize with the founding of IMOTANA. The idea for 3D-printed soccer shoes actually started on Kickstarter. In collaboration with around 1,200 supporters, the team of Benjamin Dorsch, Matthias Leibitz, Manuel Meier, and Matthias Lang spent over two years further developing the shoes.
An early 3D model of the shoes (Credit: IMOTANA)
(Credit: IMOTANA)
Cleat Guards
Professional soccer shoes, whether 3D-printed or not, should be properly maintained. Protecting the cleats is something every player should take seriously. Here, too, there are 3D-printed solutions, most notably the cleat guards from Hypsole.
The team behind Hypsole spent many years developing an optimal design for a protective structure that can perfectly cover a wide variety of cleat and shoe styles. The idea began when Jes Christian, now CEO of Hypsole and at the time still an athlete, considered what she would wear to best protect her shoes. It was important not only to achieve the right balance of function and aesthetics but also to address questions of materials and manufacturing. “We went through hundreds of design modifications and prototypes, including different materials and production processes for different parts, before landing on the current versions.”
(Credit: Hypsole)
Beyond soccer, the guards can also be used for lacrosse, baseball, softball, and rugby (Credit: Hypsole)
Both aesthetically and functionally, the cleat guards are a product designed with great care and respect for athletes. According to the manufacturer, the guards are suitable not only for soccer but for a wide range of sports. The goal is to make it as easy as possible for athletes to move from one place to another, take care of their most important equipment, and save time in the process.
Goalkeeper Gloves
Every goalkeeper knows how essential the right gloves are for both performing well and preventing injuries. One of the most important components of a goalkeeper’s glove is the so-called impact zone, which provides the keeper with stability and flexibility. Traditionally, impact zones were made from TPU or latex, but this year the glove specialist Reusch released the Attrakt Fusion Carbon 3D, a goalkeeper glove whose impact zone is entirely made of complex 3D-printed structures.
The Attrakt Fusion Carbon 3D is the first project by the nearly 90-year-old company to incorporate 3D-printed elements. Always open to new designs and improved performance, the Reusch team collaborated with Carbon to develop a unique pair of goalkeeper gloves. “3D printing gave us a unique opportunity to create a punch zone with precise energy return, improved impact response, and reduced weight,” the Goalkeeping Production Manager at Reusch told us.
(Credit: Reusch/Carbon)
The Carbon DLS technology allowed the team to create flexible, high-performance, and complex structures with smooth surfaces that would not have been possible with traditional materials and techniques. Integrating the 3D-printed structures into the soft fabric parts of the glove, however, proved challenging. As Reusch stated, “We had to redefine bonding methods, rethink how the element behaves on a flexible textile, and communicate clear performance benefits.” Close collaboration with Carbon and other manufacturing partners ultimately made it possible to achieve the ideal combination of materials and structures. The soft and flexible properties of the material were preserved, giving the team even more design freedom than expected.
In addition, the goalkeeper gloves had to meet existing safety and material compliance standards. While these standards are not particularly strict for gloves, they still need to meet the high expectations of professional athletes and developers. For this reason, the team faced a high bar in terms of flexibility, durability, and comfort for the new glove. The unique composition of the glove and the complex structures of the impact zone speak for themselves. The Attrakt Fusion Carbon 3D demonstrates the potential of 3D printing in the production of soccer equipment.
The 3D-printed structure of the impact zone (Credit: Reusch/Carbon)
Protective Face Mask
When Son Heung-min, captain of the South Korean national team, entered the court during the World Cup in Qatar, he – much to everyone’s surprise – wore a face mask. The reason? Heung-min was dealing with the aftermath of a facial injury, and the carbon mask was meant to protect his still-sensitive eye. He was not the only one, as Croatian player Josko Gvardiol also appeared wearing a mask in the game against Japan. A similar case inspired Italian soccer fan and research fellow at the Università Politecnica delle Marche, Simone Gallozzi, to write his thesis on the potential of additive manufacturing in the world of sports, specifically focusing on protective masks in soccer.
Simone Gallozzi’s protective mask (Left, Credit: Simone Gallozzi); Son Heung-min at the 2022 Qatar World Cup (Right, Credit: Maddy Meyer / FIFA)
The idea came to him when Napoli player Osimhen began wearing protective masks after a collision with another player in 2021, which led to a facial surgery. As an avid soccer fan and 3D printing enthusiast, Gallozzi explored ways to create custom masks using 3D printing technology. The masks mentioned above were likely made based on a three-dimensional model of the athletes, with carbon fibers applied layer by layer. Gallozzi, however, argued that 3D printing directly from a 3D scan could shorten this process significantly. By eliminating an intermediate step, waste could also be reduced. As Gallozzi points out, “with 3D printing, the process could be significantly faster by simply scanning the athlete’s face and producing the mask directly, without the need to create a physical model.“
In Heung-min’s case, it was uncertain for a long time whether he would even be able to play in the World Cup in Qatar. Osimhen was also sidelined for a long period due to his head injury. The protective masks live up to their name, as they allow “athletes to return to play sooner after an injury—much earlier than they would be able to without this type of protective equipment. In fact, the mask protects the injured area from further impact and helps prevent new injuries,” Gallozzi emphasizes. In his study, he designed a protective mask and printed it using PA603CF, a carbon composite material. For more information about the protective mask, you can find Gallozzi’s work HERE.
The first prototype of the mask (left) and the 3D model based on a facial scan (right). (Credit: Simone Gallozzi)
What is the Future of 3D printing in this industry?
After all these examples of using 3D printing for soccer equipment, one crucial question remains: will 3D printing continue to be used in this field in the future? Experts generally gave positive feedback. Christian highlighted that 3D printing is particularly suitable in sports for customizing equipment to fit athletes. “Bodies are so unique, and elite athletes are tasked with learning and understanding their bodies at an elite level. With that understanding comes an understanding about how, for example, one’s left foot might need a slightly wider toe box than their right,” she said when asked about the impact 3D printing could have in her area. Reusch also noted that 3D printing has enormous potential for “tailoring performance, fit, and protection.“
Interestingly, Gallozzi points out that professional sports teams, especially in soccer, could benefit from using 3D printing. He argues that budget is often not an issue for professional teams, allowing them to “fully leverage the benefits of this technology, such as extreme product customization.” Because as it stands right now: 3D printing is expensive. Because, as Reusch explaines, the manufacturing of the Attrakt Fusion Carbon 3D gloves was more costly than the company’s traditional latex or TPU gloves. Gallozzi also emphasizes the costs involved in 3D-printed production.
Professional athletes in particular could benefit from the adaptability of the technology (Credit: Brad Smith)
It is clear that, at present, additive manufacturing is not yet suitable for mass production. However, what manufacturers lose in cost advantages, they gain in customization options and modification potential, as the specific product examples show. Our interviewees also emphasize that 3D printing in sports equipment is still in its early stages. Gallozzi points out that powder-based printing technologies could be particularly promising: “with the development of advanced powder materials—such as those that incorporate carbon fiber, or combine strength, lightness, and flexibility—I believe 3D printing will play an increasingly important role in the future of sports equipment.“
Christian also highlights the potential of 3D printing for athletes of all levels. “I think it’s just going to continue to get faster, better, and cheaper, until one day in the not-too-distant-future when these kinds of customizations are available to players at all levels.” Despite initial challenges or ongoing technical hurdles, 3D printing could also enhance product properties and lead to even higher-performing equipment, like shown by the cleat protectors, shoes, masks, and gloves featured in this article. Reusch assured us that so far, only a small part of 3D printing’s potential in sports equipment has been explored. “We’re just beginning to see how it can complement traditional materials in goalkeeping.“
What do you think of this look into the world of soccer equipment and 3D printing? We sincerely thank all our interview partners who made this article possible. Let us know in a comment below or on our LinkedIn or Facebook pages! Plus, don’t forget to sign up for our free weekly Newsletter to get the latest 3D printing news straight to your inbox. You can also find all our videos on our YouTube channel.
*Cover Photo Credit: dpp Media