Amanda Knapp
Basketballs have had a uniform design for almost 100 years, but sports equipment manufacturer Wilson has recently unveiled a prototype 3D-printed airless basketball. The ball is made from an elastomeric polymer developed by Wilson and has a see-through lattice structure with hexagonal holes that allow air to pass through it. The airless design eliminates the need for inflation and overcomes issues with contraction in inflated balls due to changing environments and temperatures. Wilson's lead engineer on the project, Nadine Lippa, explained that the biggest challenge was ensuring the ball bounced similarly to traditional basketballs.
| Characteristics | Values |
|---|---|
| Manufacturing Technology | 3D printing |
| Design | Lattice structure with hexagonal holes |
| Material | Elastomeric polymer |
| Weight | Similar to a standard basketball |
| Bounce | Similar to a traditional basketball |
| Durability | High |
| Inflation | Airless |
| Cost | $2,500 |
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3D printing technology
The world's first 3D-printed airless basketball, the Airless Gen1, was created by Nadine Lippa, Wilson's manager of basketball R&D, in collaboration with her team at Wilson Sporting Goods and her husband, Dave, who worked for manufacturing partner EOS. The ball is made using industrial 3D printing technology and is designed to be used without an air pump or needle, eliminating the need for inflation.
The 3D-printed basketball features a lattice structure of small, hexagonal holes, resembling a honeycomb. This complex shape is made possible by 3D printing and contributes to the ball's bounce, which can be adjusted based on the lattice design. The lattice pattern allows for deformation and the storage of energy, similar to springs, enabling the ball to bounce back. The material used for the lattice, an elastic polymer, also plays a crucial role in the ball's bounce and durability.
The manufacturing process for the 3D-printed airless basketball involved extensive testing and retesting of different methods and materials. Lippa and her team spent five years finding the right combination of material properties and mechanical design. 3D printing was initially considered in 2018, but the material properties were not yet suitable. With advancements in technology, additive manufacturing became the sole method capable of bringing the airless prototype to life.
The 3D-printed airless basketball offers several advantages over traditional basketballs. Firstly, it eliminates the issue of air pressure loss, ensuring consistent bounce over time. Secondly, its unique structure provides a quieter bounce, making it ideal for players who want to practice without disturbing their neighbours. Additionally, the ball is expected to be more sustainable and environmentally friendly. However, it is important to note that the 3D-printed ball is not intended for official sports use and is recommended for indoor play, away from sharp objects.
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Lattice structure
The Airless Gen1 basketball from Wilson Sporting Goods is a unique ball that does not require inflation and performs just like a traditional basketball. This innovative design is driven by its lattice structure, which is a series of nodes and struts that form a framework. The lattice structure allows air to pass through the ball, giving it bounce and making it more durable.
The lattice structure of the Airless Gen1 basketball is created through 3D printing, specifically the selective laser sintering (SLS) method of additive manufacturing. This process involves using lasers to fuse layers of polymer powder into the desired 3D design. The lattice is made up of small, hexagonal holes that resemble a honeycomb shape. This complex structure allows the ball to deform and store energy, which is then released as it bounces back into its original shape.
The lattice structure of the Airless Gen1 basketball provides several advantages over traditional inflated balls. Firstly, it eliminates the need for inflation, addressing the common issue of balls eventually going flat. Secondly, the lattice structure allows for better performance in different environments and temperatures, as it is not affected by changes in air pressure. This ensures a consistent playing experience regardless of the conditions.
Additionally, the lattice structure contributes to the ball's durability and long-lasting performance. The use of elastic polymers or elastomeric polymers, as developed by Wilson, gives the ball its unique bounce and feel. The material's squishy and bouncy nature, as described by Monique McClain, a mechanical engineer at Purdue University, enhances the playing experience and sets it apart from traditional basketballs.
The Airless Gen1 basketball by Wilson showcases the potential of 3D printing and lattice structures in sports equipment design. By eliminating the need for inflation and providing a consistent, durable, and familiar playing experience, this ball has the potential to become a game-changer in the world of basketball and beyond.
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Bouncing ability
The airless basketball is designed to bounce in the same way as a traditional basketball. However, creating a ball without air that rebounds to the expected height posed a significant challenge to its designers. The bounce of a traditional basketball comes from the air pressure inside the ball. In contrast, the bounce of the airless basketball comes from its lattice structure. The lattice deforms and stores energy, which is then released as the ball bounces back up. The size of the bounce depends on the design of the lattice.
The airless basketball is made from an elastomeric polymer developed by Wilson. It has a see-through lattice structure with hexagonal holes that allow air to pass through. The lattice structure also contributes to the ball's bounce and durability. The ball was designed using 3D printing technology, with the layers building up to form the entire sphere.
The ball's unique structure and material composition give it a different feel to the hand, even while bouncing identically to a pressurized basketball. Reviews describe the sound of the airless ball as a "whoosh" as air flows through it, which is softer than the "slap-and-boing" sound of a traditional basketball. The airless ball is also heavier than a traditional basketball, which some players may find affects its performance.
The airless design eliminates the need for inflation and the issues associated with deflation, such as the ball going flat due to manufacturing defects, blunt force, or air escaping over time. It also overcomes the contraction in inflated balls caused by changing environments and temperatures, which can affect the ball's performance.
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Durability
The airless basketball is designed to be more durable than traditional basketballs. Traditional basketballs lose their bounce over time due to air escaping through the valve, manufacturing defects, or blunt force. The airless basketball is made from a unique, highly elastic material, an elastomeric polymer, that eliminates the issue of deflation and increases durability.
Wilson's airless basketball is designed to perform identically to a traditional basketball in terms of size, weight, and bounce. The ball's lattice structure, made up of hexagonal holes, allows air to pass through it and deforms to store energy, which is then released as the ball bounces back. This lattice structure is essential to the ball's performance and durability.
Nadine Lippa, Wilson's lead engineer on the project, stated that the company wanted to create a ball that did not need to be inflated and would not go flat over time. To test the durability of the airless basketball, Lippa and her team hit the ball with a baseball bat and were pleased to see that they couldn't damage it.
The airless basketball's durability also lies in its ability to withstand changing environments and temperatures. Traditional inflated balls can appear flat or play differently in cold environments due to the contraction of air, but the airless design overcomes this issue. This feature ensures that the ball maintains its performance and durability in various conditions.
While the exact material composition of the airless basketball is not publicly known, it is believed to be a mixture of something "squishy and bouncy." The ball's unique structure and material properties contribute to its durability, making it a long-lasting and high-performance sports equipment.
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Sustainability
The Wilson Airless Gen1 basketball is a sustainable innovation in the basketball industry. Firstly, it is made using 3D printing technology, which simplifies the supply chain. With 3D printing, manufacturers can produce balls on demand, reducing waste from overestimation or underestimation of demand. This technology also allows for a decentralised manufacturing process, with 3D printers located across the globe, reducing the environmental impact of transporting goods.
The ball is made of a single material, a polymer lattice structure, compared to the five materials used in a traditional basketball. This reduction in materials further simplifies the supply chain and reduces the environmental impact of sourcing multiple materials. The lattice structure, with its hexagonal holes, also provides a natural grip, eliminating the need for additional grip materials.
The Airless Gen1 basketball is also designed to be long-lasting and durable. Traditional basketballs can pop or become deflated over time, requiring replacement. The Airless Gen1, however, does not need to be inflated and is less likely to pop, extending its lifespan. This durability reduces the need for frequent replacements, further contributing to sustainability by decreasing resource consumption and waste generation.
Furthermore, the Airless Gen1 basketball challenges the conventional design of a basketball, pushing the boundaries of existing technology. By creating a playable ball without the need for inflation, Wilson has demonstrated that innovation and sustainability can go hand in hand. This encourages other manufacturers to explore sustainable alternatives, fostering a culture of environmental responsibility within the industry.
While the Airless Gen1 basketball is a step towards sustainability, it is important to consider the entire lifecycle of the product. The environmental impact of the materials used, the energy consumption during 3D printing, and the end-of-life disposal or recycling options should be assessed to fully understand the sustainability of this innovative basketball.
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Frequently asked questions
An airless basketball is a ball that does not need to be inflated and performs similarly to a traditional basketball in terms of size, weight and bounce.
The airless basketball is made using 3D printing technology. It is made from an elastomeric polymer developed by Wilson, which has a see-through lattice structure with hexagonal holes that allow air to pass through it.
The airless basketball eliminates the need for an air pump or needle, as it does not require inflation. It also solves the issue of deflation caused by blunt force, manufacturing defects, or air escaping over time. Additionally, it is expected to be more durable and sustainable than traditional basketballs.
The airless basketball, specifically the Airless Gen1, was invented by Nadine Lippa, Wilson's manager of basketball R&D. It took six years to develop and utilised cutting-edge software and 3D printing technology.
