OECHSLER revolutionizes large-scale production of American football helmets with plastic-based 3D printing technology

From Prototype to mass production in 100 days
  • From prototype to mass production of damping elements for innovative American football helmet from market leader Riddell in 100 days
  • Named test winner by US Football League initiative: 3D mesh product from OECHSLER improves protective effect of Riddell helmets
  • As the production technology of the future, additive manufacturing offers OECHSLER great potential for growth

OECHSLER AG, a leading plastics technology group with a global presence and headquarters in Ansbach/Middle Franconia, Germany, is using its global fleet of 3D printers to produce the plastic mesh helmet damping elements for the innovative "Riddell SpeedFlex Diamond" American football helmet. Thanks to OECHSLER's proven expertise in plastic-based 3D printing technology with machines from Silicon Valley 3D printing pioneer Carbon Inc, Riddell was able to quickly bring a new generation of products to market and realize a competitive advantage. Riddell is recognized as a leader in helmet technology for American football. From prototype to the start of large-scale production by OECHSLER took less than 100 days - and that was despite the pandemic outbreak in the meantime and the resulting challenges during the course of the project.

Within the scope of the project, OECHSLER Additive Manufacturing capacities were used both at the Ansbach-Brodswinden site and at the Taicang plant in China.

3D lattice design replaces foam damping elements

The special feature of the new SpeedFlex Diamond helmet from Riddell is the 3D grid construction for damping elements, which substitutes the previously used foam in the helmet inserts. The grid consists of thousands of rod-shaped elastic connections and takes into account the latest findings in impact analysis. It enables bionic structures that make the helmet customizable, lighter, more comfortable, and more breathable. In particular, they improve player protection by optimizing the helmet's shock-absorbing properties, which can be custom-programmed to meet the needs of different areas, such as the forehead, temples, and back of the head.

As part of its "Play Smart, Play Safe" initiative, the US Football League NFL has therefore chosen the helmet model produced with the OECHSLER components as the test winner based on an independent comparison.

Individualized damping properties for different applications

The damping property of the grille structure is programmable via the geometry of the grilles, the thickness (or gauge) of the grille bars, and the size of the grilles. This allows different areas of the helmet to be equipped with different damping properties, thus increasing protection. OECHSLER has been producing plastic-based 3D mesh structures for various applications for three years. The project with Riddell demonstrates the versatile applicability and volume scalability of 3D printing, for example in the context of replacing or improving existing products, and is thus an inspiration for new areas of application.

In principle, the cushioning technology used can also be used in other applications, from sports (e.g. shoes, equestrian sports) to protective clothing (e.g. police and firefighters) and road traffic (e.g. motorcycle and bicycle seats).

"Plastic-based 3D meshes will replace many solid and foam materials because they release functional potential through weight reduction and the optimization of damping properties that are not possible with conventional materials. With this technology, OECHSLER is opening up new growth markets in the key industries of automotive, sporting goods, medical technology, and manufacturing, and establishing a second core technology alongside injection molding."

Claudius Kozlik
Chief Executive Officer at OECHSLER

Fast and reliable large-scale production of innovative parts

With the innovative damping elements, OECHSLER demonstrates its expertise in plastic-based additive manufacturing and proves its ability to industrialize projects globally and produce more than 1 million parts per year in large series. OECHSLER uses several alternative plastic-based 3D printing technologies from leading equipment manufacturers in its additive manufacturing machinery and operates one of the world's largest plastic-based 3D printer fleets at its three sites in Ansbach (EU), Acworth, Georgia (NA), and Taicang, China (Asia/Pacific).

Post-processing critical to success for high-volume 3D printing

In addition to the actual 3D printing of the components, OECHSLER's multi-stage post-processing is a key success criterion for industrialized production. In this, the parts produced in the additive process receive their defined mechanical properties in various work steps - including cleaning and heat treatment, among others. In recent years, OECHSLER has built up extensive expertise in post-processing in the additive series production of components and is thus one of only a few companies worldwide that can offer 3D printing mass production globally at all. OECHSLER AG's German production site was one of the first in the world to be certified by TÜV Süd as part of the 3D printing service competence for industrial additive manufacturing sites.

Huge market potential in many key industries

Dr. Claudius M. Kozlik, CEO of OECHSLER, said: "Plastic-based additive series production is still a very young technology and many industries are only now discovering its possibilities. In the meantime, beyond prototypes, additive processes can also be used to produce veritable large series in a highly flexible manner on several continents in a very short time. Plastic-based 3D meshes will replace many solid and foam materials because they release functional potential through weight reduction and the optimization of damping properties that are not possible with conventional materials. With this technology, OECHSLER is opening up new growth markets in the key industries of automotive, sporting goods, medical technology, and manufacturing, and establishing a second core technology alongside injection molding."

Additive manufacturing is one of the fastest-growing production technologies of the future. Already today, OECHSLER has a global and established position in the market with several prestigious projects realized together with innovative pioneers in their industries. The increasing demand across industries for ever lighter materials, flexible designs, and the most sophisticated functions open up dynamic growth prospects for 3D mesh printing.

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