US-based 3D printing company CRP USA has partnered with the USA Bobsled/Skeleton team (USABS) to develop a novel bobsled design for the 2026 Olympic Winter Games.
The partnership between CRP USA and USABS originated through a connection with a local carbon fiber products company. In this collaboration, CRP USA assumed the role of supplying USABS with 3D printed functional parts designed specifically for racing bobsleds. Crucial elements, including push handles, hand grips, and seats, were developed using CRP’s Windform family of high-performance materials. These components play a pivotal role in optimizing the performance of bobsleds and ensuring the safety of athletes.
“The big advantage of 3D printing for the USA Bobsled/Skeleton team is that no mold’s need to be made,” said Marc van den Berg, Technology and Equipment Lead for USABS. “So a huge amount of time is saved and the costs remain much lower. Not to mention a much faster delivery of the parts because no mold is required. The 3D process also has many advantages because more complex parts can be made.”
USABS headquarters, push handles, definitive version, during the assembly phase. Photo via USABS.
Enhancing Accuracy in Icy Conditions
The ability to adhere to stringent guidelines regulating the shapes and sizes of bobsled pieces was one of the main hurdles that the USABS team had to overcome. Van den Berg highlighted the importance of complying with these standards, while simultaneously guaranteeing resistance to stress. The considerable forces acting upon a bobsled at the start of a race, combined with the possibility of crashes, necessitated the use of resilient and flexible materials to avoid component failure.
Carbon fiber-infused composites supplied by CRP Technology, named Windform XT 2.0 and Windform SP, surfaced as ideal materials for the 3D-printed bobsled components. This collaboration facilitated the quick manufacture of push handles, grips, and seats, eliminating the need for costly molds. This, in turn, empowered the USABS team to carry out multiple tests, iterate designs, and swiftly implement any required alterations.
In their assessment of these particular components, CRP USA performed an extensive analysis that eventually identified Windform SP as the most apt construction material. This decision was based on its impressive characteristics, which encompass exceptional resistance to impact, vibration, and deformation. Noteworthy properties that testify to its effectiveness include a density of 1.106 g/cc at 68 °F and 20 °C, a melting point of 380 °F and 193.3 °C, a Heat Deflection Temperature (HDT) of 1.82 Mpa at 368 °F and 186.5 °C, and a tensile strength of 11,000 psi and 76.10 Mpa. Moreover, Windform SP showcases an elongation at break of 11.38%, further demonstrating its adaptability and robustness.
“The athletes have waited a long time to get back on the ice and begin competing,” says Curt Tomesevicz, Director of Sport Performance for USABS. “So, it was very rewarding to see so many great results. It is the reward of a lot of hard work in the off-season.”
Expressing satisfaction with the collaboration, Marc van den Berg highlighted the efficiency of the 3D printing process. The speed of execution and delivery by CRP USA allowed the team to thoroughly test the components for stress resistance and ergonomics, ultimately achieving optimal results.
The 3D printed bobsled parts debuted at the IBSF North American Cup (NAC) in November 2023, marking a significant moment in winter sports, says the company.
3D printing playing a significant role in the sports industry
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