BASF Forward AM + Prosilas Case History

A highly productive and longstanding collaboration has been established between Prosilas and BASF Forward AM over the years. This partnership has given rise to esteemed projects, including the research and production of Philipp Plein’s Skeleton Sole and the comprehensive Lube Volley Case Study.

What are the Lattice Test Pads, and what is their purpose?

Lattice Test Pads are the 3D printed version of the are Ultrasim® 3D Lattice Library.

They are 3D-printed TPU blocks divided into sections that specify the cell size and beam diameter. Each section provides information regarding the structure classification and hardness.

These Lattice Test Pads come in three types: footwear, seating, and protection. Each type features a lattice structure suitable for its respective application, such as shoe soles, seat cushions, headrests, or various protective elements.

Contribution of Prosilas 

Prosilas has been involved in the lattice characterization process, providing various prints of the 3D Lattice Test Pad samples that allowed BASF Forward AM to conduct in-depth studies. These data were essential for furthering the progress of the software.

To ensure that the software consistently delivers high-quality results over time, specific machine parameters have been established for the fabrication of these structures. These parameters have been designed to set a printing standard, ensuring that software users obtain consistent and reliable results. This commitment to quality and consistency is crucial for the success and effectiveness of the software.

Lube Volley, the team

A tangible collaboration, thanks to 3D printing

When Enrico Diamantini and Ivan Zaytsev, two prominent athletes from the club, expressed their need for new hand protection devices during games, the relationship between Lube Volley and Prosilas evolved beyond a simple sponsorship. Prosilas immediately utilized its expertise in 3D printing to develop an innovative, customized, and tailored solution for both players.

‘We took the opportunity to get even closer to the world of medicine and sport, trying to develop a truly useful and professional application,’ says Vanna Menco, CEO Prosilas

Diamantini required an alternative to the temporary brace he had been using to support his injured right little finger, while Zaytsev needed a replacement for the medical tape he typically used to stabilize his fingers during high-impact phases of the game.

The previous solutions had limitations in terms of materials, lacking of technical performance, reusability, and customization, which resulted in a sub-optimal playing experience. However, with the advent of 3D printing, Prosilas believed that they could overcome these limitations and produce custom-made and reusable devices with exceptional speed and precision.

For Diamantini, the old brace was rigid, bulky, and therefore uncomfortable. The negative impact on his ball touch led him to use it sporadically and only for the minimum required time. Similarly, Zaytsev sought a custom-made, reusable alternative that provided better sensitivity compared to traditional medical tape.

Through their collaboration with Prosilas, both athletes found the solution they were looking for, addressing their specific needs and improving their playing experience on the court.

Fast and successful product development

 The initial phase of the project focused on acquiring the 3D models of Diamantini and Zaytsev’s hands using the Gom Atos 5 3D scanner, which involved scanning plaster casts. Subsequently, the design phase commenced, incorporating reverse engineering techniques to accurately model customized designs. These designs were tailored to protect and immobilize the injured joint in one case, and provide comfortable support in the other. The devices underwent testing and, with valuable feedback from the athletes, were progressively refined to achieve the best possible results.

“The responsiveness of additive technology is truly remarkable. The initial contact with the players took place in October 2022, and after just five rounds of improvements, we were able to arrive at the final version of the devices for both players within a very short timeframe,” states the CEO of Prosilas.

TPU protective devices being tested on the cast of Ivan Zaystsev’s right hand

3D design through reverse engineering of protective devices

TPU protective devices for Enrico Diamantini in three different thicknesses: 1, 1.5 and 2 mm

Testing phase and results

“The results achieved through the utilization of additive technology are undeniably positive,” remarks Vanna Menco. “This is further corroborated by the outcomes of resistance tests conducted on the material by our supplier, BASF 3D Printing Solutions.”

 The testing phase was a critical step in the process. Collaborating with BASF, an effort was made to replicate a volleyball game in a laboratory setting. This involved evaluating the material’s chemical resistance, short and long-term durability, as well as color stability.

TPU testing samples

The remarkable durability and strength of the custom 3D-printed devices can be deduced from the absence of significant degradation observed during testing. This ensures the longevity of the product even under repeated stress and in special chemical conditions. Apart from the scientific findings, the enthusiastic feedback from the athletes themselves confirmed the positive results and the significant improvement in playability and game feel.

The combination of improved performance, stable feel, durable material, and complete customization results in an overall increase in comfort for athletes during competition, leading to an enhancement in playing performance.

Customization has become an essential trend in the world of ultra-competitive champions, and additive solutions go above and beyond by offering specific shapes and characteristics tailored to each individual athlete’s needs.

Working with BASF 3D Printing Solutions

BASF 3D Printing Solutions, operating under the Forward AM brand, is a division of BASF New Business GmbH that is specialized in advanced materials, system solutions, components, and services in the field of 3D printing. With a lean structure and an agile mindset akin to a start-up, BASF 3D Printing Solutions is well-equipped to cater to the diverse needs of various industries by offering innovative and customized services. The company works closely with other departments within BASF, research institutes, universities, start-ups, and industrial partners to serve customers in automotive, aerospace, consumer goods, and other product categories.

The partnership with BASF 3D Printing Solutions holds significant strategic importance for Prosilas, further solidified by the mutual respect between the two companies.

 “Prosilas brings extensive experience in printing our flexible TPU materials, ensuring the consistent delivery of superior quality parts,” explains Tobias Haefele, Product Manager Powder Bed Fusion. “We greatly appreciate their exceptional creativity,” he continues, “and their attitude to push the limits of the 3D printing market, paving the way for new applications, which align with our vision. With their specialist knowledge and established presence in sectors such as fashion, they have earned our trust as a reliable partner in consistently delivering exceptional products over the years. At BASF 3DPS, we are excited to continue our journey with Prosilas, forging a promising future for additive manufacturing.”