3D-PRINTED SHIN GUARD WITH CUSTOMIZED DAMPING AND REINFORCED ZONES

Abstract

The present disclosure relates to a 3D-printed shin guard (100) with adjustable cushioning and reinforced zones for improved protection and comfort. The shin guard comprises an ergonomically shaped cushioning shell (102) designed to conform closely to the user's leg, optionally a flexible textile layer (104) that additionally comes into direct contact with the skin, and one or more reinforced zones (106A-F) that provide different levels of impact resistance and / or cushioning. The cushioning shell (102) has a slightly concave, bionic hollow design that provides flexibility while maintaining strength. It is made of an orthopedic material, preferably thermoplastic polyurethane (TPU), and is manufactured using additive manufacturing processes such as selective laser sintering (SLS).It offers lightweight, durable protection and caters to the different preferences and impact absorption requirements of a user / player.

Description

AREA OF TECHNOLOGY This disclosure relates generally to protective sports equipment. In particular, it relates to shin guards incorporating a bionic structure and adaptable material properties to improve their impact absorption, comfort, and adaptability. The shin guard(s) are specifically designed for use by soccer players and optimized for additive manufacturing processes. BACKGROUND Traditional shin guards typically consist of a rigid plastic shell that protects the shin from impacts. However, due to their inflexibility and rigidity, these shin guards cannot conform to the shape of an individual user's / player's leg, often resulting in discomfort and impaired ball control as they shift during play. Furthermore, traditional shin guards are usually secured with straps or compression sleeves, creating layers on the leg that further impair ball feel. Existing shin guard systems have significant limitations that affect player comfort, protection, and usability. Many shin guards feature a rigid outer shell paired with a soft inner layer, resulting in a lack of adaptability to the individual shin shape of the player, even the same player. This rigidity can cause discomfort during extended wear, as the guards often fail to fully conform to the leg contours, causing them to shift during play and reducing both comfort and protection.Furthermore, the multi-layered structures used to deflect impact, as is currently the case, increase volume and weight, which can impair mobility and ball control, making current shin guards cumbersome for users / players seeking lightweight, high-performance options. While some guards offer multiple stiffness options, these settings are typically applied uniformly across the entire guard, meaning impact distribution is not well optimized. This uniformity can result in areas of excessive stiffness or softness, causing discomfort or insufficient protection in critical areas. Furthermore, the individual customization of current shin guards is generally limited to aspects such as size and shape, rather than functional, performance-oriented adjustments like zonal reinforcement or variable cushioning. This limitation prevents players from customizing the guard's protective properties to cover specific impact zones. Additionally, surface protrusions added for cushioning, such as pyramid or cone shapes, can contribute to discomfort or snagging. Moreover, while some earlier models featured elastomer materials and geometries for cushioning, they lacked zonal impact protection tailored to different areas of the shin, ideally on an individual basis.The standardized design approach fails to account for the varying impact forces occurring at different parts of the shin, potentially leaving some areas insufficiently protected or excessively rigid, thus compromising comfort and protection in high-impact zones. Therefore, while existing shin guards offer some adjustability, they don't provide a truly ergonomic, lightweight, and adaptable solution. The lack of advanced zonal protection, structural flexibility, and efficient surface finishing limits these shin guards in their ability to support optimal player performance and comfort. Therefore, there is a need to address the aforementioned technical disadvantages of existing shin guard technologies, offering improved comfort and adaptability and ensuring effective protection tailored to the preferences and impact requirements of the individual user. SUMMARY Consequently, the present invention aims to provide an innovative solution for a shin guard, preferably designed for soccer players, utilizing advances in additive manufacturing processes. This invention aims to create a shin guard that offers superior comfort, enhanced protection, and customizable features tailored to the needs of individual athletes and their legs. Through the use of flexible materials, preferably thermoplastic polyurethane (TPU), and a bionic design, the shin guard adapts to the contours of the individual leg, ensuring a good fit that minimizes slippage and discomfort during sports / games. The inclusion of different levels of cushioning in various zones provides targeted impact absorption, effectively protecting vulnerable areas while allowing optimal mobility.Furthermore, the design allows for the seamless integration of personalized logos and customizations directly into the manufacturing process, enabling players to express their individuality without compromising performance. Ultimately, this disclosure aims to revolutionize the shin guard market by delivering a product that prioritizes both safety and comfort, allowing athletes to achieve peak performance. The objective of this disclosure is achieved through the solutions provided in the attached independent claims. Advantageous implementations of this disclosure are further defined in the dependent claims. Accordingly, the present invention generally provides an adjustable, shock-absorbing shin guard that combines ergonomic design with advanced material properties and manufacturing processes for improved user comfort and protection. The shin guard according to the invention comprises a slightly concave, cushioning shell with one or more reinforced zones that offer different levels of cushioning based on predefined degrees of hardness. Optionally, a flexible textile layer on the inside ensures a comfortable feel against the skin. Furthermore, the invention enables integrated branding through a centrally placed logo, designed with a hardness ranging from strong to hard to ensure a long service life in high-stress areas. The logo can be oriented diagonally, horizontally, centered, or similarly, allowing for flexible design. According to the invention, the shin guard is manufactured using Selective Laser Sintering (SLS) from a flexible material, in which powder material is layered in combination with a CO2 laser in a heated build chamber; thermoplastic polyurethane (TPU) is preferred. This process allows for precise control of the hardness levels in different zones as well as detailed surface finishing. Post-processing techniques, including compressed air and bead blasting, followed by surface densification, minimize surface roughness.Optionally, additional steps such as dyeing or chemical smoothing can further enhance the final appearance. This innovative approach results in a shin guard with a high degree of customization, durability, and functional protection. In one aspect of the invention, a 3D-printed shin guard with customized padding and one or more reinforced zones is provided. In one embodiment, the shin guard comprises a shock-absorbing shell ergonomically shaped to conform closely to the user's leg and one or more reinforced zones incorporated into the shock-absorbing shell, configured to provide varying degrees of impact resistance and cushioning. Optionally, the shin guard includes a flexible textile layer on the inner surface of the shock-absorbing shell. The optional flexible textile layer makes direct contact with the user's skin. In one embodiment, the shock-absorbing shell has a slightly concave configuration. The concave, continuous design of the shock-absorbing shell, extending to the side edge, provides maximum coverage and protection around the leg. An optional flexible textile layer, positioned on the inner surface of the shock-absorbing shell for direct contact with the user's skin, offers a soft and comfortable feel while enhancing overall comfort. Reinforced zones provide varying levels of shock absorption tailored to different areas of the leg. By incorporating these different levels of shock absorption, the shin guard effectively absorbs impacts in high-risk areas, providing enhanced protection, while simultaneously improving comfort and flexibility where less protection is needed. In one embodiment, the cushioning levels are provided in at least two, preferably at least three, different hardness levels, namely selected from medium, strong, and hard, to accommodate different player preferences and impact requirements. "Medium" offers a balanced level of cushioning, providing flexibility and comfort for moderate protection. "Strong" offers greater cushioning for improved impact absorption in areas requiring additional protection. The "Hard" level is designed as a robust material for maximum resistance and durability in high-impact areas, ensuring the highest level of protection where it is most critical. These different hardness levels allow for targeted impact absorption and optimal comfort, tailored to different zones of the shin guard to meet the specific protection needs of each area. In one embodiment, the cushioning shell features a bionic hollow structure. This bionic, 3D-printed hollow structure reduces the weight of the shin guard while simultaneously providing cushioning. This offers protection against kicks and increases wearing comfort. In one embodiment, the shin guard consists of a flexible orthopedic material, preferably thermoplastic polyurethane (TPU), which increases comfort by adapting to the user's / player's leg while providing the necessary support and impact resistance. In one embodiment, a logo or other customizable design element is integrated into a central or designated reinforced zone of the shin guard. The shin guard can be customized with logos and / or branding through embossing and / or raised details seamlessly integrated into the 3D-printed process. This design feature allows for expanded personalization and / or branding options, enabling logos to be added as three-dimensional elements that are both aesthetically pleasing and durable. The embossed logos add texture without compromising the structural integrity of the shin guard, allowing for the creation of a unique look that reflects the identity of individuals or teams while maintaining the high-performance properties of the shin guard. A technical design according to the invention provides for a logo to be incorporated into the center of the shin guard, where it features a level of cushioning ranging from strong to hard. This placement ensures that the logo is both clearly visible and reinforced for added durability in a high-stress area. The logo can be positioned in various orientations—diagonally, horizontally, or centrally—thus allowing for flexible adaptation to aesthetic or brand-related preferences. This integration combines visual appeal with functional strength, making the logo a prominent and durable part of the shin guard's technical structure. In one embodiment, the zoned reinforced structure can be adjusted both horizontally and vertically to provide different damping levels in different directions. In one embodiment, the shin guard is manufactured using additive manufacturing processes. The additive manufacturing process utilizes selective laser sintering (SLS), employing powder fusing and layer-by-layer techniques. The selective laser sintering (SLS) process begins with the layer-by-layer application of powder from a powder reservoir onto a lowering build platform, leveling the powder to create a flat surface. Once the layer is prepared, a CO2 laser is used to create the components or layer protrusions by moving along the desired contours and fusing the powder with the underlying material, preferably thermoplastic polyurethane (TPU). The process takes place in a heated build chamber, which warms the material, preferably thermoplastic polyurethane (TPU), to temperatures just below its melting point to facilitate fusing.After each layer is complete, the powder is carefully fused with the previous layer to create the final object. After the printing process, excess powder must be removed from the components. This is initially done manually with compressed air, followed by a blasting technique combined with compressed air to remove any remaining fine powder. To achieve a smoother surface, the finished component is compacted with another medium, minimizing surface roughness. Optionally, further post-processing methods such as dyeing or chemical smoothing can be used to further refine the surface and enhance the appearance of the printed part. For structural design, the model is projected onto a shin guard model and divided into segments. These segments are then categorized into different hardness grades based on predefined parameters that influence the microstructure of the printed object. The segments are marked accordingly, if necessary.For features such as a logo, a solid, continuous layer is first printed separately and then, shortly before the object is finished, rejoined to the structured volume to ensure seamless integration. This process enables the production of highly detailed, customized, and durable components with varying degrees of hardness and surface quality. The preferred material used in the context of the invention is thermoplastic polyurethane (TPU). This material possesses advantageous vibration damping and resilience. Through its 3D printing manufacturing process, thermoplastic polyurethane allows for local customization of the thermoplastic material to meet the forces exerted during sports, particularly soccer, such as blows / kicks to the shin, while maintaining flexibility where required.The 3D printing of TPU allows for the creation of macrostructures of varying densities in the shin guard according to the invention, which in turn address the specific local needs of a shin guard. For example, softer areas / zones with a lower TPU density can provide relief through increased flexibility and transition seamlessly into other, firmer areas with a higher TPU density, thus offering locally harder, less flexible protection. These and other aspects of the embodiments according to the invention will be further clarified when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, although they specify preferred embodiments and numerous specific details thereof, serve for illustration and not as limitations. Many changes and modifications can be made within the scope of the embodiments contained herein without departing from their basic principles, and the embodiments contained herein encompass all such modifications. BRIEF DESCRIPTION OF THE DRAWINGS The present embodiments will be better understood from the following detailed description with reference to the drawings, in which: Fig. 1 shows an exemplary 3D-printed shin guard with customized padding and reinforced zones according to the present disclosure. Fig. 2 illustrates an exemplary side view of the shin guard of Fig. 1 according to the present disclosure. Fig. 3 illustrates an exemplary perspective bottom view of the shin guard of Fig. 1 according to the present disclosure. Fig. 4 illustrates an exemplary perspective side view of the shin guard of Fig. 1 according to the present disclosure. Fig. 5 illustrates an exemplary cross-sectional view of the shin guard of Fig. 1 according to the present disclosure. Fig. 6 illustrates an exemplary cross-sectional view of the shin guard of Fig. 2 according to the present disclosure.Figure 7 illustrates an exemplary cross-sectional view of the shin guard of Figure 3 according to the present disclosure. Figure 8 illustrates an exemplary enlarged cross-sectional view showing the internal structure of the shin guard of Figure 1 according to the present disclosure. Figure 9 illustrates, by way of example, the shin guard of Figure 1 according to the present disclosure. DETAILED DESCRIPTION The embodiments herein and their various features and advantageous details are explained in more detail with reference to the non-limiting embodiments illustrated in the accompanying drawings and described in detail in the following description. Descriptions of known components and processing techniques are omitted to avoid unnecessarily obscuring the embodiments contained herein. The examples used herein are intended only to facilitate understanding of how the embodiments herein can be implemented in practice and, moreover, to enable those skilled in the art to implement the embodiments herein in practice. Accordingly, the examples should not be interpreted as limiting the scope of the embodiments contained herein. The present disclosure provides a technical solution that overcomes the problems encountered in the prior art and offers improved comfort, protection, and adaptability in shin guards. The bionic hollow structure of the shin guard reduces weight while maintaining strength, and the flexibility of the orthopedic material, preferably TPU, offers varying degrees of hardness for optimal comfort and protection. Furthermore, customization options, including logos or unique designs, can be integrated directly during the manufacturing process. This comprehensive solution overcomes the limitations of conventional shin guards by improving comfort, durability, and user personalization.In the context of the invention, an “orthopedic material” is a material suitable for orthopedic problem solutions and, depending on its intended use, serves to stabilize and / or relieve and / or immobilize and / or protect certain body structures, in particular the shinbone of a user. According to the invention, thermoplastic polyurethane (TPU) is the preferred orthopedic material, in particular 3D-printed thermoplastic polyurethane. Now, referring to Fig. 1: Fig. 1 shows an exemplary 3D-printed shin guard with customized padding and reinforced zones according to the present disclosure. In this embodiment, the shin guard 100 comprises a slightly concave cushioning shell 102 with a pronounced and continuous structure that extends to the side edge and provides an ergonomic fit on the user's leg for comfort and stability. In this embodiment, the cushioning shell 102 also includes a flexible textile layer 104 (not shown in Fig. 1) that comes into contact with the user's skin. The structure of the cushioning shell 102 is divided into several reinforced zones 106A-F. Each reinforced zone is intended to provide a different degree of cushioning and impact absorption depending on its location and the required specific hardness.Reinforced Zone 106A is the central area, housing a logo and reinforced for increased hardness and durability. Reinforced Zones 106B-F represent additional areas with customized reinforcement. These zones have varying shapes and orientations around the perimeter of the Shin Guard 100. Each reinforced zone can be horizontally and / or vertically reinforced, or a combination thereof, allowing for highly customizable levels of cushioning across the Shin Guard 100. Specifically, Reinforced Zones 106C and 106F are designed with adjustable properties, enabling modification in both horizontal and vertical directions. This adjustability provides flexibility in the placement and orientation of these zones, allowing for precise customization to better conform to the user's leg contours or to enhance protection and comfort in specific areas.This adaptable design increases the versatility of the shin guard, making it suitable for a variety of leg shapes and protection needs. The structure is hollowed out in certain sections, reducing overall weight without compromising strength—a characteristic of bionic design. In this particular example, the shin guard measures 51.57 mm at its widest point, providing shin protection while maintaining a lightweight, comfortable profile. Now, with reference to Fig. 2: Fig. 2 illustrates, by way of example, a side view of the shin guard of Fig. 1 according to the present disclosure. The side view of the shin guard 100 shows the slightly concave cushioning shell 102. This concave curvature is designed to conform closely to the shape of the user's leg, thus increasing comfort and stability when worn. The shin guard 100 has, by way of example, a total length of 162.06 mm and thus provides sufficient protection along the shin; however, this is not limited. The concave design of the cushioning shell 102 ensures that the shin guard 100 fits snugly around the shin, which allows for an even distribution of impact forces over the shin guard 100 while maintaining a lightweight shape.This ergonomic curvature helps to minimize discomfort during movement and ensures a closer fit to the leg, reducing the likelihood of slipping or sliding during physical activity. Now, with reference to Fig. 3: Fig. 3 shows, by way of example, a perspective bottom view of the shin guard of Fig. 1 according to the present disclosure. The cushioning shell 102 has, by way of example, a concave shape with a width of 103.37 mm and a maximum depth of 15.48 mm and is designed to wrap around the shin and provide a snug fit, which increases stability and comfort during use; however, it is not limited in this respect. Fig. 3 shows the optional flexible textile layer 104, which comes into contact with the user's skin. Now, referring to Fig. 4: Fig. 4 shows, by way of example, a perspective side view of the shin guard of Fig. 1 according to the present disclosure. Fig. 4 shows the slightly concave cushioning shell 102 with a pronounced and continuous structure extending to the side edge, providing an ergonomic fit on the user's leg for comfort and stability. Reference is now made to Fig. 5: Fig. 5 shows, by way of example, a cross-sectional view of the shin guard from Fig. 1 according to the present disclosure. The components and features described in Fig. 1 also apply to Fig. 5 and provide a coherent representation of the design and structural elements of the shin guard. Now, with reference to Fig. 6: Fig. 6 illustrates, by way of example, a cross-sectional view of the shin guard of Fig. 1 according to the present disclosure. The cross-sectional view shows the structural thickness and layering of the damping shell 102 with reinforced zones 106A-F embedded therein. The reinforced zone 106A is preferably made thicker to provide additional impact damping where impacts are most likely. Now, referring to Fig. 7: Fig. 7 illustrates, by way of example, a cross-sectional view of the shin guard of Fig. 3 according to the present disclosure. The various reinforced zones 106A-F correspond to sections with different densities or materials and offer targeted protection where required; TPU is the preferred material. Now, with reference to Fig. 8. Fig. 8 illustrates, by way of example, an enlarged cross-sectional view showing the internal structure of the shin guard of Fig. 1 according to the present disclosure. The section shows the reinforced zone 106A, which is preferably thicker to allow additional impact damping where impacts are most likely. Now, with reference to Fig. 9. Fig. 9 illustrates, by way of example, the shin guard of Fig. 1 according to the present disclosure. The components and features described in Fig. 1 also apply to Fig. 9 and provide a consistent representation of the design and structural elements of the shin guard. The foregoing description of the specific embodiments will disclose the general nature of the embodiments contained herein so completely that others, applying their current knowledge, will be able to easily modify and / or adapt such specific embodiments for different applications without departing from the general concept. Therefore, such adaptations and modifications should be understood within the scope of the meaning and equivalent range of the disclosed embodiments. It is understood that the language or terminology used herein serves for descriptive purposes and not for limitation. Although the embodiments herein have been described with regard to preferred embodiments, the person skilled in the art will recognize that the embodiments herein can be implemented in practice with modifications within the scope of the appended claims. LIST OF REFERENCE NUMBERS 100 Shin guards 102 Cushioning shell 104 A flexible textile layer (optional) 106A-F Reinforced zones In the above-mentioned context, the present invention also relates to the following consecutively numbered embodiments: 1. A 3D-printed shin guard (100) with adjustable cushioning and one or more reinforced zones, comprising: - a cushioning shell (102), wherein the cushioning shell (102) is ergonomically shaped to conform closely to a user's leg; - optionally, a flexible textile layer (104) additionally provided on the inner surface of the cushioning shell (102), wherein the flexible textile layer (104) directly contacts the user's skin; and - one or more reinforced zones (106A-F) integrated into the cushioning shell (102), wherein the one or more reinforced zones (106A-F) are configured to provide different degrees of impact resistance and / or cushioning. 2.1. The shin guard (100) according to embodiment 1, characterized in that the cushioning shell (102) has a slightly concave configuration. 2. The shin guard (100) according to embodiment 1 or 2, characterized in that the cushioning levels are provided in at least two, preferably at least three, different degrees of hardness, namely selected from medium, strong, and hard, to meet different user preferences and / or impact requirements. 3. The shin guard (100) according to one of embodiments 1 to 3, characterized in that the cushioning shell (102) has a bionic hollow structure. 4. The shin guard (100) according to one of embodiments 1 to 4, characterized in that the shin guard (100) is made of a flexible orthopedic material, preferably thermoplastic polyurethane (TPU). 5.The shin guard (100) according to one of embodiments 1 to 5, characterized in that a logo or other customizable design element is integrated in a central or designated zone of the shin guard (100). 7. The shin guard (100) according to one of embodiments 1 to 6, characterized in that the zone-wise reinforcement can be adjusted horizontally and / or vertically to provide different degrees of damping in different directions. 8. The shin guard (100) according to one of embodiments 1 to 7, wherein the reinforced zone (106A) has increased hardness and / or durability, and / or wherein the reinforced zones 106C and / or 106F are configured with adjustable degrees of damping to exhibit modification in the horizontal and / or vertical direction. 9.The shin guard (100) according to one of embodiments 1 to 8, characterized in that the shin guard (100) is manufactured using an additive manufacturing process. 10. The shin guard (100) according to one of embodiments 1 to 9, characterized in that the additive manufacturing process comprises selective laser sintering (SLS) with powder fusing and layer-by-layer techniques.

Claims

A 3D-printed shin guard (100) with adjustable cushioning and one or more reinforced zones, comprising: - a cushioning shell (102) wherein the cushioning shell (102) is ergonomically shaped to conform closely to a user's leg; - optionally a flexible textile layer (104) additionally provided on the inner surface of the cushioning shell (102), wherein the flexible textile layer (104) directly contacts the user's skin; and - one or more reinforced zones (106A-F) integrated into the cushioning shell (102), wherein the one or more reinforced zones (106A-F) are configured to provide different degrees of impact resistance and / or cushioning. The shin guard (100) according to claim 1, characterized in that the damping shell (102) has a slightly concave configuration. The shin guard (100) according to claim 1 or 2, characterized in that the damping levels are provided in at least two, preferably at least three different degrees of hardness, namely selected from medium, strong and hard, to meet different user preferences and / or impact requirements. The shin guard (100) according to one of claims 1 to 3, characterized in that the damping shell (102) has a bionic hollow construction. The shin guard (100) according to one of claims 1 to 4, characterized in that the shin guard (100) consists of a flexible orthopedic material, preferably thermoplastic polyurethane (TPU). The shin guard (100) according to one of claims 1 to 5, characterized in that a logo or other customizable design element is integrated in a central or designated zone of the shin guard (100). The shin guard (100) according to one of claims 1 to 6, characterized in that the zone-wise reinforcement can be adjusted horizontally and / or vertically to provide different levels of damping in different directions. The shin guard (100) according to one of claims 1 to 7, wherein the reinforced zone (106A) has increased hardness and / or durability, and / or wherein the reinforced zones 106C and / or 106F are configured with adjustable damping levels to provide modification in the horizontal and / or vertical direction. The shin guard (100) according to one of claims 1 to 8, characterized in that the shin guard (100) is manufactured using an additive manufacturing process. The shin guard (100) according to one of claims 1 to 9, characterized in that the additive manufacturing process comprises selective laser sintering (SLS) under powder fusion and layer-by-layer techniques.

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