Ayrton Oneill
Wilson Sporting Goods has developed an airless basketball called the Airless Gen1, which is made using 3D printing technology. The ball is formed using selective laser sintering (SLS), a process that sinters powder layer by layer until a complete sphere is formed. The lattice-like structure, which is made up of eight panel-like lobes, does not require inflation and eliminates the need for air retention. The Airless Gen1 weighs around 610 grams, falling slightly under the maximum regulation weight of 620 grams, and has been designed to fit the performance specifications of a regulation ball in terms of weight, size, and bounce.
| Characteristics | Values |
|---|---|
| Manufacturing Technology | 3D printing |
| Manufacturing Process | Selective laser sintering (SLS) |
| Design | Two layers of a honeycomb-like structure with a centimeter of depth between them |
| Weight | 610 grams |
| Bounce | Same as an indoor/outdoor ball |
| Sound | Whooshing sound when it hits the ground |
| Customization | Small customization panel for printing details |
| Colors | Black, brown, and off-white natural |
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What You'll Learn
Wilson Airless Gen1 basketball
The Wilson Airless Gen1 basketball is a groundbreaking innovation in basketball design. It is the product of six years of rigorous testing and cutting-edge technology, employing 3D printing and a unique never-flat design. This basketball challenges convention by performing without the need for air, a feature that sets it apart from traditional basketballs.
The Airless Gen1 basketball is crafted with meticulous attention to detail, utilising 32 Pantone and material chips to create a distinct colour for each ball. This innovative design ensures that the basketball retains its shape and performance capabilities without relying on air pressure. By eliminating the need for inflation, the Wilson Airless Gen1 basketball offers a consistent and reliable playing experience.
The absence of air in the Wilson Airless Gen1 basketball offers several advantages. Firstly, it eliminates the inconvenience of deflation, ensuring that players no longer need to worry about underinflation or the time-consuming task of inflating their basketballs. This feature promotes uninterrupted practice and gameplay, enhancing the overall playing experience.
Additionally, the Airless Gen1 basketball's design showcases Wilson's commitment to pushing the boundaries of sports technology. By utilising 3D printing technology, Wilson has created a basketball that challenges traditional design norms. The result is a basketball that not only performs exceptionally but also stands as a testament to the potential of innovative sports equipment design.
The Wilson Airless Gen1 basketball is more than just a ball; it represents a step towards the future of basketball. Its unique characteristics offer a glimpse into the possibilities of improved performance, durability, and convenience. With this groundbreaking design, Wilson has created a basketball that not only meets but surpasses the expectations of players, setting a new standard for the sport.
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3D printing technology
The airless basketball, also known as Airless Gen 1, was developed by Wilson Sporting Goods and is the brainchild of their manager of basketball R&D, Nadine Lippa. With a PhD in sports and high-performance materials, Lippa and her team utilised cutting-edge software and technology to design and test the airless basketball over six years. The result is a basketball that challenges convention, performing exceptionally well even without air.
The ball's surface features a lattice of small, hexagonal holes, resembling a honeycomb structure. This complex shape is made possible by 3D printing, which allows for the creation of intricate and deformable structures. The lattice design is key to the ball's bounce, as it stores and releases energy in a spring-like manner. This unique structure also contributes to a quieter bounce, producing a soft "whoosh" sound as air flows through the ball.
The material used for the lattice is an elastic polymer, chosen for its highly elastic and durable properties. While Wilson has not disclosed the exact composition, it is described as a mixture of something "squishy and bouncy". This material not only provides the necessary bounce but also gives the ball a weight comparable to that of a standard basketball. The use of 3D printing technology allows for experimentation with different materials and filaments, such as PLA Flex, TPE, and TPC, to achieve the desired performance characteristics.
The airless basketball offers several advantages over traditional basketballs. Firstly, it eliminates the need for pumps and needles, providing a convenient and ready-to-use experience for players. Secondly, the ball is expected to be more sustainable due to its longer-lasting bounce and the potential for on-demand printing, reducing excess product and shipping emissions. However, one notable drawback is the high cost of the airless basketball, which, at $2,500, is significantly more expensive than a standard basketball.
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$165.99 $225.99
Air retention
The Wilson Airless Gen1 basketball is a direct evolution of the prototype unveiled at the 2023 NBA Slam Dunk event. The airless basketball is created using 3D printing technology and comes in three colours: black, brown, and an off-white natural. The ball weighs around 610 grams, falling slightly under the maximum regulation weight of 620 grams.
The airless basketball is designed to eliminate the biggest pain point in ball manufacturing: air retention. The 3D-printed ball is formed using selective laser sintering (SLS), with the lattice work constructed in eight panel-like "lobes" that do not require any inflation. The ball is made up of two layers of a honeycomb-like structure, with a centimeter of depth between the two layers.
The production process for the airless basketball includes printing, smoothing, dyeing, and sealing. Each ball has a small customization panel, allowing Wilson to print details such as specific numbering. The lattice work has also undergone slight modifications, with engineers adding holes to the channels to speed up the manufacturing and post-processing timeframe and create more consistency in ball performance.
The final choice of materials for the airless basketball features a laser sintered powder of a proprietary custom elastomeric material, specifically suited for the basketball's needs. The ball offers the performance specifications of a regulation ball in weight, size, and bounce, with the added benefit of enhanced air retention due to its unique construction.
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Sound and feel
The sound and feel of the airless basketball are the two aspects that differ the most from a conventional basketball. The familiar "slap-and-boing" sound of a traditional basketball is replaced by a "whooshing" sound as the airless ball moves through the air, followed by a “smack” when it hits the ground. The absence of air in the ball contributes to this unique sound profile.
The feel of the ball also varies from that of a conventional basketball. The raised bumps and texture of classic leather basketballs are distinct and provide a particular tactile experience. The airless ball, on the other hand, has a smoother surface due to the 3D printing process. While it still retains the channels of a traditional ball, the layer lines of the SLS 3D printing are visible upon close inspection, giving it a distinct texture.
The weight and bounce of the airless basketball are also worth noting. The Gen1 ball weighs around 610 grams, slightly under the maximum regulation weight of 620 grams. When compared to an indoor/outdoor ball, the Gen1 ball bounced to the same height, demonstrating comparable bounce characteristics. This consistency in bounce performance is achieved through the lattice structure of the airless ball, which eliminates the need for inflation and provides a uniform response across different environments, regardless of variations in atmospheric pressure.
The use of 3D printing technology allows for precise control over the ball's characteristics, including weight, size, and bounce. The lattice work, constructed in eight panel-like "lobes," contributes to the ball's performance and eliminates the need for inflation. The specific material composition, which Wilson has not yet disclosed, also plays a role in achieving the desired bounce and durability.
Overall, while the airless basketball differs in sound and feel from a traditional basketball, it aims to provide a comparable, if not enhanced, performance. The elimination of air retention issues and the consistency in ball behaviour across varying environments are significant advantages that this innovative design brings to the game.
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Manufacturing process
The manufacturing process of the airless basketball is a groundbreaking innovation in the sports equipment industry. Wilson, the company behind the airless basketball concept, has developed this product over several years, utilising cutting-edge software and 3D printing technology.
The airless basketball eliminates the traditional inflated rubber bladder found in conventional basketballs. Instead, it features a transparent 3D-printed lattice shell, crafted from advanced materials like TPE (thermoplastic elastomer) and potentially TPU. This lattice structure is formed through selective laser sintering (SLS), where the ball is built layer by layer until the entire sphere is shaped. The lattice design provides the necessary bounce and weight, mimicking the characteristics of a standard basketball.
The manufacturing process involves spreading a bed of powder, typically TPU powder, which is then fused using lasers. This process, known as additive manufacturing or industrial-level 3D printing, creates a series of nodes and struts that form the framework of the ball. The powder bed is swept across, and a laser etches the pattern in two dimensions. This process is repeated, building up the three-dimensional structure of the ball. After removing the excess powder, the ball undergoes sealing and dyeing, using a smoothing technique developed by DyeMansion. The dye penetrates and reacts with the polymeric surface, resulting in a smooth and colourful finish.
The airless basketball is then sent for rigorous testing to ensure it meets performance, durability, and visual appeal standards. This testing phase includes inspections by officials, NBA representatives, and players themselves, ensuring that the ball performs consistently and feels similar to traditional basketballs. The ball's unique lattice structure provides enhanced durability and a natural bounce, making it suitable for various playing environments and skill levels.
The manufacturing process of the airless basketball offers several advantages over traditional methods. Firstly, it reduces waste and the chance of producing failed parts. Secondly, it simplifies the supply chain by requiring fewer materials, and it enables global distribution of manufacturing satellites. Lastly, it provides cost savings by reducing the amount of leather required and consolidating the construction process into a single machine and material setup.
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Frequently asked questions
An airless basketball is a basketball that does not need to be inflated. It is made using 3D printing technology and is constructed in eight panel-like "lobes".
The basketball is made up of two layers of a honeycomb-like structure. The lattice work—constructed in eight panel-like “lobes”—simply doesn’t need any inflation.
The Airless Gen1 basketball is formed via some form of plastic powder. The final choice features a laser sintered powder of a proprietary custom elastomeric material.
