3D-Printing Firm Sent Arm Brace to the Super Bowl

When the Carolina Panthers needed a customized 3D-printed brace to protect the arm of star linebacker Thomas Davis in this year’s Super Bowl, we simply said, “You need it when?” and 36 hours later, it was on Davis’ arm and miraculously, he was on his way to the big game.
 
But let’s back up to the beginning of the story.
 
Thomas Davis is one tough athlete. Prior to this latest injury, which had taken place two weeks before the Super Bowl, Davis had battled back from three ACL tears. Reportedly, when he broke his forearm in the NFC Championship Game win over Arizona and needed a six-inch plate and screws, he vowed to play in the Super Bowl. The “internal cast” was doing its job, it just needed to be protected. That’s when it came time for his trainers and team doctor to get creative.
 
Thomas’ team reached out to a few creative thinkers such as Scott Perone, co-founder of 3D-Elite who wondered whether PORON XRD, a lightweight, thin, and breathable material that’s engineered for repeated impact and shock absorption, could do the trick. 3D-Elite contacted WhiteClouds, which has the depth and breadth of experience, as well as the equipment to produce the complicated design.
 
A team of technicians, materials engineers, and designers mobilized for the 30-hour printing job. Company expertise combined with the right technology produced this fully custom exact fit brace. It was apparent why a personalized custom solution was needed. NFL players are like modern-day gladiators. Their physical size and muscular stature does not accommodate “off-the-shelf” bracing applications. The ability to print personalized and custom exact-to-scale from a 3D image scan of Davis’ arm was the perfect solution.
 
The WhiteClouds team points out these key components of the brace designed for Thomas Davis:

• There were approximately 5,100 layers in the print
• Each layer was approximately 16 microns thick.
• The inner lining and main body of the brace were made of a black, rubber-like material that has tensile strength and can be tear resistant.
• The Poron XRD was applied by 3D-Elite and went between the brace and the players arm. When Whiteclouds designed the brace, it was offset 3.0mm from his arm to accommodate the layer of Poron XRD.

 
As far as the company knows, Super Bowl 50 marks the first time an NFL player has used a 3D-printed brace on the field. Although three other “regular” braces were given a try, Davis preferred the 3D-printed brace and chose to use it on the all-important day. Although the Panthers did not emerge victorious, the day was a huge win for 3D-printing technology, as the brace demonstrated a real-world application.
 
The 3D brace isn’t the first medical device printed by WhiteClouds. The company has been selected by clients to create diverse devices, including 3D-printed models of patient anatomies for pre-surgical planning and educational use. Medical models and product training with medical partners are on the horizon for the company.
 
Generally speaking, the company views tremendous opportunities for 3D printing in these medical-related areas:

• Personalized exoskeletons and sports armor (e.g., Davis’ customized brace)
• Facial surgery and rhinoplasty—3D-printed models that will be much more compelling than a 2D rendering
• Prosthetics and orthotics—Rapidly growing fields with much promise
• Pre-surgical planning, measuring, and patient education
• Consumer models—From CTs and MRIs, WhiteClouds can print replica body parts, organs, and bones.
• Implantables and organ replacements will become a reality as the technology is evolving at rapid speeds.

 
The only obstacles in the industry? Although 3D printing has advanced in dramatic fashion over just the past couple of years, a lack of compatible materials could limit the technology’s ability to reach its full potential. Certain materials considered a great match for 3D printing, such as UV-cured resins, are adversely affected by heat, which could rule them out.
 
It’s likely that 3D printing, however, will revolutionize the entire field of medical device design and production. With a quick scan and a 3D print, traditional manufacturing is rapidly evolving into personalized custom solutions. The popular saying “one size fits all” will no longer be; each individual will have a custom solution.
 
And if current market trends are right, you may soon be filling a prescription at the printer instead of the pharmacy.