Comprehensive structural evaluation of composite materials in 3D-printed shin guards

This study introduces a novel approach to designing and fabricating lightweight football shin guards, leveraging advanced digital anatomical capture of players' shins and 3D printing techniques. Using Polyethylene terephthalate glycol (PETG) and carbon fiber (CF) composites, the 3D-printed shin guards showcased enhanced tensile, compressive, and flexural properties. Impressively, the patterned structure facilitated a 42 % weight reduction compared to its solid counterpart. Mechanical tests confirmed the consistent behavior of the printed samples, independent of their raster orientation. This consistency emphasizes the promise of expanded 3D printing utility in sports gear production. Surface and compositional evaluations were carried out using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS), revealing a uniform fiber distribution. Notably, at 70 % and 30 % infill densities, PETG/CF met the predefined criteria; in the solid structure, its compressive strength overshadowed its tensile strength yet remained below its flexural strength. The pattern structure, particularly at 0 degrees orientation, showed marked tensile advantages over the solid format. With the fundamental role of shin guards in preventing football injuries, this research paves the way for optimized protection, as many players presently utilize shin guards made from PETG, CF, or potent PETG/CF combinations.