Game, Set, Print: 3D Printing’s Surprising Role in Sporting Goods and Beyond

Charles R. Goulding and Preeti Sulibhavi uncover how 3D printing is transforming U.S. industries — from sports gear to medical devices — by slashing reliance on imports and unlocking fresh innovation.

On May 29, 2025, Fabbaloo published our article that highlighted the potential of new databases in identifying 3D printing opportunities. Shortly after, the New York Times utilized a similar approach to detail major Chinese imports into the U.S., revealing, in our view, categories ripe for domestic 3D printing innovation. While not directly drawing a correlation between the two, the coincidence allows readers to focus on sectors like sporting goods, musical instruments, car parts, toys, plastic products, and seats, where U.S. manufacturers can leverage 3D printing to reduce reliance on imports and foster local production.

Sporting Goods and Rackets

The U.S. market for racket sports is substantial, encompassing tennis, badminton, squash, and pickleball. 3D printing offers avenues for customization, rapid prototyping, and localized manufacturing in this sector.

1. Customized Tennis Rackets: Companies are exploring 3D printing to produce tennis rackets tailored to individual player preferences, optimizing weight distribution and grip design.
2. Pickleball Paddle Innovations: Startups are utilizing 3D printing to create pickleball paddles with unique core structures, enhancing performance and durability.
3. Badminton Shuttlecock Production: 3D printing enables the production of shuttlecocks with precise aerodynamic properties, allowing for consistent performance and reduced manufacturing costs.

Musical Instruments

The musical instrument industry benefits from 3D printing through the creation of complex geometries and customized designs.

1. Yamaha’s 3D Printed Wind Instruments: Yamaha has been experimenting with 3D printing to produce wind instrument components, achieving intricate designs that enhance sound quality.
2. Custom Guitar Bodies: Luthiers are using 3D printing to craft guitar bodies with unique shapes and internal structures, offering musicians personalized aesthetics and acoustics.
3. Drum Hardware Components: 3D printing allows for the creation of lightweight and durable drum hardware, such as lugs and mounts, improving portability and performance.

Automotive Parts

The automotive industry is increasingly adopting 3D printing for both prototyping and end-use parts, enhancing efficiency and customization.

1. BorgWarner’s 3D printed auto parts: BorgWarner has partnered with Cornell Engineering to transition from tool steel to 3D printing plastic for select companies, which has been enabled by the advent of widespread high-temperature 3D printable materials.
2. Czinger 21C Hypercar: The Czinger 21C is a groundbreaking vehicle, primarily constructed using 3D printing technology. This approach allows for rapid production of complex components, reducing weight and improving performance.
3. Ford’s 3D Printed Brake Components: Ford has integrated 3D printed brake components into its high-performance vehicles, such as the Shelby GT500, enhancing braking efficiency and reducing production time.
4. Porsche’s Custom Seats: Porsche has developed 3D printed bucket seats with customizable firmness levels, offering drivers personalized comfort and support.

Toys

The toy industry benefits from 3D printing through rapid prototyping and the ability to produce complex designs.

1. Bambu Lab’s CyberBrick: Bambu Lab introduced CyberBrick, a 3D-printable toy system integrating reusable and programmable electronic components, fostering creativity and STEM learning.
2. Customized Action Figures: 3D printing enables the production of personalized action figures, allowing consumers to create toys that reflect individual preferences and likenesses.
3. Educational Puzzle Toys: Educators are using 3D printing to create custom puzzle toys that aid in teaching complex concepts through interactive learning.

Plastic Products

Plastic products span various industries (including plastic utensils like spoons), and 3D printing offers a sustainable and efficient manufacturing method.

1. Home Appliance Components: Manufacturers are 3D printing plastic parts for home appliances, reducing lead times and allowing for rapid design iterations.
2. Medical Device Housings: 3D printing facilitates the production of plastic housings for medical devices, enabling quick responses to design changes and regulatory requirements.
3. Consumer Electronics Casings: Companies are using 3D printing to produce plastic casings for consumer electronics, allowing for customization and reduced inventory costs.

Seats

Seating solutions across various sectors are being revolutionized by 3D printing through enhanced ergonomics and customization.

1. Porsche’s 3D Printed Seats: As mentioned, Porsche’s 3D printed seats offer customizable firmness and improved ventilation, enhancing driver comfort.
2. Oechsler and TECHART Collaboration: Oechsler partnered with TECHART to develop 3D printed car seats with enhanced ventilation and damping properties, improving performance on racetracks.
3. Office Chair Prototypes: Furniture designers are using 3D printing to prototype office chairs with ergonomic designs, allowing for rapid testing and refinement.

The Research & Development Tax Credit

The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.

3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes are typically eligible expenses toward the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software can also be an eligible R&D expense. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.

Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.

Conclusion

The integration of 3D printing across these industries presents a significant opportunity for U.S. manufacturers to reduce dependence on imports and foster domestic innovation. By embracing additive manufacturing, companies can achieve greater customization, efficiency, and responsiveness to market demands.

As 3D printing technology continues to evolve, its applications will likely expand further, offering solutions to complex manufacturing challenges and contributing to the growth of various sectors within the U.S. economy.