3D printed gloves offer Paralympian racer comfort and customization | VoxelMatters - The heart of additive manufacturing

American Paralympian Tatyana McFadden currently holds 20 medals from the Paralympics (eight of which are gold medals), making her one of the most decorated Paralympic athletes in history. In recent years, the wheelchair racing superstar has benefitted from an upgrade to her equipment: customized 3D printed gloves that provide her with greater comfort, durability and even performance. The gloves, made using CRP USA‘s Windform XT 2.0 material and SLS 3D printing, will undoubtedly be on showcase as McFadden competes in the upcoming Paris 2024 Summer Paralympic Games.

McFadden has been using 3D printed wheelchair gloves since 2015, when her team switched to the process that allowed for greater customization and lightweighting. Prior to that, McFadden’s wheelchair gloves, which must withstand the high friction created by the hand-to-wheel contact, were made using mold kits, however this process fell short of expectations and required lots of maintenance.

As McFadden herself explained: “My first wheelchair racing gloves were called ‘harness gloves’. They were shaped like thumbs, and made of heavy-duty fabric with rubber padding. Their softness made me feel the impact every time I hit the hand ring. By the 2008 Paralympic Games, my team and I began making hard gloves. We would take plastic beads, melt them in a pot of boiling water, and then mold the plastic to my hands. This process took days to perfect. Sometimes we would have to start over and throw the whole plastic glove back in the water. Once perfected, I did not let the gloves out of my sight because they would melt if left in the car or in the heat for too long. Over time, the plastic would wear down, so we made the gloves thick, but they were heavy.”

3D printing offered an alternative, capable of printing a glove fit to the racer’s hand and at a level of quality that could withstand the friction and intensity of wheelchair racing. As mentioned, McFadden and her team first experimented with 3D printed gloves in 2015 and were immediately impressed by the printed gloves’ lightweight structure. In 2016, the Paralympian started working with CRP USA to improve on the glove design and properties.

The CRP USA team discussed McFadden’s concerns and requirements for the best possible performance, including durability, lightness, comfort and weather resistance. “When I met with the CRP USA team, we also talked about heat, rubber, weather effects, and straps for the gloves so they can stay in my hands better,” McFadden said. “When competing outside, we face various weather conditions, and I want to be ready for anything. My gloves have cracked in the past. My strokes produce a lot of force when I hit the hand ring, and my previous gloves lasted less than a year. I also wanted a better way to add rubber to the hand rings. The CRP USA team listened to my needs and managed to satisfy them in the best possible way.”

In the end, the 3D printed gloves were made using laser sintering technology and CRP Technology’s Windform XT 2.0 material, a carbon fiber reinforced composite known for its high stiffness and impact resistance. Through certain design adaptations, including internal structuring, CRP USA was also able to successfully minimize the weight of the gloves while still maintaining their strength and durability. In the end, the 3D printed gloves weighed just 100 grams, marking a 50% reduction compared to non-printed counterparts.

CRP USA also found a way a superior way to bond the rubber facing for the gloves to the 3D printed structure. The rubber used was sourced off the shelf and was cut to size before being attached using a structural adhesive. According to McFadden, the rubber component of the glove is far more secure than previous iterations of her equipment, which makes maintaining the gloves far easier. She commented: “Before, I had to super glue and duct tape the rubber for extra durability, but it would peel off because it was glued by hand. Now, with CRP USA’s solution, the rubber is so secure that only tools or a machine can remove it. I no longer worry and can focus on training and competing for Team USA.”

While the 3D printed composite gloves have offered benefits like greater durability, comfort and performance, the CRP USA team is still working with McFadden to take the wheelchair gloves to the next level, with a focus on improving the grip and comfort even more, particularly in wet conditions. With the Paris Paralympics right around the corner, keep an eye out for McFadden’s upcoming performances in the Para Track and Field competition.