SYZMIK Introduces 3D Printed Elastomeric Lattice Padding in Protective Headwear

Sports gear manufacturer SYZMIK Sports has introduced its X7C+ Protective Headband, featuring a 3D printed elastomeric lattice core engineered to reduce impact forces in non-tackle football and high-mobility sports. Developed in collaboration with industrial 3D printing company Carbon, the internal padding uses Carbon’s Digital Light Synthesis technology and EPU 45 resin to replace traditional moulded foam inserts.

EPU 45 Elastomer and Multi-Zonal Lattice Architecture

The core component of the headband, branded as MATRIXFRD, relies on a strain-rate sensitive elastomeric polymer. Under normal wear, the geometric lattice structure flexes freely to provide comfort, ventilation, and a low-profile fit. When subjected to sudden energy or impact, the strain-rate sensitivity of EPU 45 causes the material structure to stiffen locally, absorbing and dispersing forces more effectively than conventional foam padding.

According to SYZMIK, transitioning from uniform foam pads to a computationally zoned 3D printed lattice yields up to a 77 per cent reduction in concussion risk metrics without increasing pad thickness. The variable geometry allows different zones of the headband to offer distinct levels of resistance and flexibility, tailored specifically to the structural demands of head impact protection. The finished lattice remains visible through a translucent outer shell, highlighting the internal geometric array.

Seamless Bonding and Shell Construction

Beyond the internal printed lattice, the headgear incorporates distinct manufacturing techniques to maintain structural durability without adding weight or restrictive seams. The flexible outer chassis consists of injection-moulded polymer segments joined through ultrasonic welding rather than traditional stitched thread, eliminating common failure points along seam lines.

A moisture-wicking synthetic textile is bonded directly to the flexible shell. Precision-cut expansion zones in the fabric allow multi-directional stretch during movement, while an internal geometric grip pattern helps maintain position on the wearer’s head. The entire assembly weighs between 80 and 95 grams depending on size, earning a 5-Star safety rating from the Virginia Tech Helmet Lab.

What This Means for South African Makers

While the X7C+ relies on industrial dual-cure resin hardware, the underlying concept of using elastomeric lattice structures for impact protection is increasingly relevant to desktop 3D printing. Flexible materials such as thermoplastic polyurethane (TPU) and flexible UV-cure resins are widely accessible to local makers, workshops, and small product design studios across South Africa.

Understanding how lattice geometry changes material behaviour allows South African engineers, sports equipment designers, and hobbyists to create custom protective gear, internal helmet liners, ergonomic grips, and vibration dampers on desktop FDM and resin machines. Slicing applications and generative CAD plugins now offer tools to generate infill lattices with variable densities, enabling local developers to prototype energy-absorbing parts without investing in costly injection moulds.

DC3D’s Take

The integration of 3D printed lattices into commercial sportswear underscores a practical shift away from uniform solid foams toward tailored digital structures. By leveraging strain-rate sensitive elastomers and multi-zonal geometry, product designers can balance comfort, breathability, and functional protection within compact form factors.

For makers and designers experimenting with flexible filaments or resin lattices, this development demonstrates the value of structural design over raw material volume. While achieving exact strain-rate responses requires specialised polymer chemistry, desktop printing setups can still achieve substantial energy absorption and weight savings by tuning lattice density, wall thickness, and unit cell geometry.