Additive manufacturing enables the fabrication of personalized protective equipment with locally tailored mechanical properties. In this work, a low-cost scan-to-print workflow is proposed for the fused filament fabrication (FFF) of personalized dual-zone shin guards combining a stiff outer load-distribution layer with a compliant inner energy-absorbing layer. Subject-specific leg geometry was acquired via structured-light 3D scanning and used to design a shin guard with two 3.5 mm thick zones (total thickness 7 mm). Foamable filaments of PLA, ASA, and TPU were employed to manufacture unfoamed and foamed regions by controlling extrusion temperature. Mechanical performance was assessed through three-point bending tests and dynamic finite element impact simulations. Unfoamed PLA and ASA exhibited flexural strengths of approximately 88 MPa and 72 MPa, respectively, while foaming reduced these values by about 74%. Dual-zone configurations partially restored stiffness, reaching 41 MPa for PLA and 29 MPa for ASA. TPU showed lower flexural stresses with a smaller reduction of 23% upon foaming. Impact simulations revealed maximum deformations of 1.97 mm and 2.02 mm for PLA and ASA outer zones, respectively, while TPU exhibited large deformations leading to penetration of the 3.5 mm thick inner layer. The results demonstrate that dual-zone designs manufactured via foaming-enabled FFF can effectively balance stiffness, weight, and impact response for personalized shin guard applications.
Koltsakidis et al. (Wed,) studied this question.