Case Study: Bernstein Innovation achieves scalable, customized shin guard production with 3D Systems

3D Printing Gives Bernstein Innovation the Home Team Advantage in Product Development

Bernstein Innovation GmbH, a Linz-based SLS 3D printing service bureau founded by Jakob and Klaus Schmied, set out to solve the common problem of ill-fitting shin guards and to showcase the design potential of additive manufacturing. Determined to move beyond prototypes and help clients reduce start-up costs, the team launched ZWEIKAMPF as their first in-house consumer product to prove how 3D technology can enable better-fitting, performance-focused gear.

They combined player scanning and iterative design with 3D Systems’ sPro 140 SLS printer using DuraForm PA shells and custom-cut XRD impact inlays to create a three-part, anatomically fitted shin guard offered in three sizes and customizable finishes. The process yields 300–350 parts per build, passed compliance and rigorous durability tests, and demonstrated a scalable, low- to mid-volume production workflow with clear market potential.

Bernstein Innovation

Viktoria Reidl

Product Development