How Is 3D Printing Being Used at the Paralympic Games?

3D Printing at the Paralympic Games

Parasports rely on technological aids to varying degrees. From wheelchairs and prostheses to sports equipment, technological progress is helping athletes to exceed their limits and further develop para-sports.

“Sport is the best medicine,” explains Heinrich Popow, former German track and field athlete and multiple Paralympic medal winner. At the same time, he emphasizes the importance of technology in parasports. “The use of aids is a sport in its own right,” says Popow and he therefore advocates a separation between Olympic sport and Paralympic sport, which relies on technological aids and therefore pursues its very own performance limits and goals. “That’s the beauty of Paralympic sport. You notice how the performance density is getting bigger and bigger because you’re doing performance-oriented sport,” emphasizes Popow.

A combination of different technologies is often used to exceed performance limits. For Paralympians, this opens up completely new sports and also new possibilities in their existing discipline. 3D printing, for example, in combination with other technologies – e.g. 3D scanning and design optimization – can contribute to greater ergonomics, mobility and comfort and thus promote optimal performance in competition and training. This is why more and more athletes are embracing the benefits of 3D printing and over the last few years we have seen an increasing number of 3D printed aids at the Paralympic Games, including of course state-of-the-art prosthetics and orthotics, but also equipment such as ergonomic grips and gloves in the cycling and wheelchair competitions.

Swiss athlete Flurina Rigling, who will be competing in the cycling events at the 2024 Summer Paralympic Games in Paris with 3D-printed shoes (and who already won a bronze medal on August 29), sums up the benefits of 3D printing for athletes: “This innovation helps me enormously,” says Rigling. “You have to imagine it: I used to have a single leather shoe. Once it was wet, I had to let it dry first. Now the 3D printer shoes are produced comparatively quickly and they are much lighter than the old ones. That makes a huge difference to me.”

The fact that more and more high-performance materials can be processed using 3D printing processes also increases comfort for athletes. Multi-material printing can be used to produce components with soft and hard parts, for example. Other advantages of 3D printing include individualization and a high degree of customizability. The printed objects can be made to measure and are then perfectly tailored to the respective person; on the other hand,  plus they can also be adapted very quickly if, for example, the person’s needs change due to an injury.

And given the vast range of athletes’ aids and parts, it goes without saying that various 3D printing processes and materials can be used. This is why the Repair Service Center has numerous technological resources on site to carry out repairs. Notably in terms of processes, we find FDM, SLS and MJF.

FDM 3D printing is used primarily for prototyping and test parts in order to ensure that sockets, especially, will perfectly fit the athletes (as being too tight or too loose can have a negative impact). Meanwhile, for many prostheses that will be used directly by the athletes, MJF 3D printing and SLS are popular choices to create high-performance parts for parasports.

This brings us to materials. As you might expect, what is used differs greatly depending on the part being made. Standard materials for 3D printing, such as nylon and ABS can be used, especially for prototypes, but carbon fiber-reinforced materials are used much more frequently for end-use parts. This is because with composite parts, reinforcing fibers (including CF and GF) can be embedded either specifically or continuously in a thermoplastic matrix. In 3D printing, the reinforcing fibers can be placed precisely, which means that the stiffness of the parts can be specifically adapted and lightweight parts can be printed at the same time. Furthermore, metal 3D printing is also used in Parasport. Titanium, for example, is used to print personalized prostheses, which are then much stronger than standard prostheses.

One example of this is Anna Grimaldi, a Paralympian from New Zealand, who uses a 3D-printed titanium prosthesis to safely lift 50 kilograms. Which method and material is chosen often depends on the individual case, as the athletes’ focus is on performance and comfort. Sometimes a combination of different technologies (CNC, injection molding, 3D printing) is used to create the best solution for the athlete. Nevertheless, the numerous examples from recent years show that 3D printing is gaining ground at the Paralympic Games

The transformative impact of 3D printing in the sports for the disabled: Empowering athletes through innovation

Personalized assistive devices

Traditional assistive devices (such as prosthetics, orthotics or support frames) often fail to fully meet the unique physical structure and functional requirements of each athlete. However, the emergence of 3D printing has made it possible to provide customized solutions. Through human body scanning and digital modeling, engineers can design perfect-fitting devices specifically for athletes, achieving the best comfort, weight distribution and biomechanical efficiency.

For instance, carbon fiber running blades for sprinters or custom grips for rock climbers can all be continuously optimized and improved while maintaining durability and flexibility. This highly personalized design not only enhances athletic performance but also significantly reduces the risk of injury caused by ill-fitting equipment.

Performance-enhancing competition gear

3D printing materials are lightweight yet highly durable, enabling athletes to push the boundaries in competitions. For instance, components such as bicycle frames, wheelchair spokes, or rowing boat supports can be redesigned to maximize efficiency while adhering to the rules.

For instance: Aerodynamically optimized wheelchair components, or adjustable prosthetic accessories specifically designed for archery, can all be tested through rapid prototyping, thereby accelerating the innovation cycle. Moreover, 3D printing enables athletes to adjust their equipment for specific competitions to better suit their physical condition and competition strategies.

Skill Training Aid Tools

For disabled athletes, mastering technical movements often requires customized training tools. 3D printing can produce training equipment that simulates real environments, helping athletes train safely under controlled conditions.

For instance, adjustable balance trainers designed for amputee skiers, tactile feedback systems developed for visually impaired swimmers, or modular grips tailored for strength training athletes. These tools enable athletes to conduct independent training, experiment with optimization, and build muscle memory while reducing their reliance on expensive equipment.

Unique medals and souvenirs

Apart from the competitive aspect, 3D printing can also bring creativity and inclusiveness to events such as the Paralympics. The event organizers can customize medals, trophies and souvenirs to celebrate the spirit of the competition.

For instance, textured medals with Braille engraving, or trophies made from recycled materials that incorporate elements of disability sports, not only show respect for the athletes’ achievements, but also symbolize the integration of technology and the resilient spirit of humanity. Such innovations have greatly enhanced the cultural significance and emotional value of the Paralympic events.

Enhancing the accessibility of assistive technologies

For a long time, the high cost and limited access to assistive devices have made it difficult for many athletes, especially those in developing regions, to obtain the necessary support. However, 3D printing has broken this barrier by providing opportunities to more people through localized and low-cost manufacturing methods.

The design documents can be shared globally. The community can produce the required equipment as needed without relying on centralized chemical plants, thereby reducing waste, shortening delivery time, and giving athletes the ability to repair or modify the equipment themselves.

For instance, wheelchair users in remote areas can use open-source designs to print replacement parts or personalized seats, thereby achieving greater autonomy and inclusiveness.

Create a more inclusive future

3D printing technology is rapidly integrating into the sports for the disabled and is driving them towards a more personalized, equalized and innovation-driven future. By providing each athlete with a solution that is more fitting, more efficient and more accessible, additive manufacturing not only enhances the competitive level but also highlights the combination of humanistic care and technological power carried by sports.

*This article originally appeared on 3Dnatives. Madeleine P is the original author of this piece.

3D printing on demand

Have parts to make? Get free instant quote today.

Get instant quote