Custom Protective Face Mask

An end-to-end workflow in 7 days: white-light 3D scanning with ±0.1 mm accuracy, reverse engineering and tooling design in Autodesk® Fusion™, 3D printing of the positive mold and carbon-fiber manufacturing through lamination with controlled fiber orientation (0°, 90°, ±45°).

Every hour counts in elite sports. Our workflow eliminates costly physical iterations and compresses the full engineering and manufacturing cycle into one week.

01 · Diagnosis and Brief (Days 1–2). Receipt of the medical diagnosis (craniofacial CT). Definition of the injury area, required offloading zones and conditions of use. NDA signed if required. Coordination of the scanning session at the club's facilities or medical center.

02 · 3D Scanning — Anatomical Capture ±0.1 mm (Handheld Scanner · White Light · ±0.1 mm). Digitization of the player's face with a handheld white-light scanner (±0.1 mm accuracy). A non-invasive 5–10 minute process with no contact with the injured area. Motion compensation algorithms remove artifacts from breathing micro-movements. The result is a watertight polygon mesh exported as STL/OBJ for the modeling phase.

03 · Reverse Engineering and CAD Design in Autodesk Fusion (Days 2–3). The point cloud is imported into Autodesk Fusion for reverse engineering: mesh cleanup, generation of the parametric solid and definition of the offloading offset (+3 mm calibrated over the fractured area). The orbital visual profile is designed to preserve peripheral and lower field of vision, critical for ball control. Digital iteration until the geometry is validated without making a single physical part.

04 · Tooling Design and Fabrication (3D Mold) (Days 3–4). The positive mold is designed in Autodesk Fusion from the validated anatomical model. The mold is produced by additive manufacturing (FDM/SLS) in high-temperature-resistant materials compatible with the epoxy resin curing cycles. Release agents are applied to ensure clean separation after curing.

05 · Carbon-Fiber Lamination — Fiber Orientation (CFRP · Days 4–6). Hand lamination over the mold with carbon-fiber fabric plies in a quasi-isotropic sequence: 0° plies (axial stiffness against frontal impacts), 90° plies (resistance to lateral buckling) and ±45° plies (torsional control against oblique impacts). The laminate is consolidated by vacuum bagging and oven curing to maximize fiber fraction and eliminate porosity.

06 · Machining, Finishing and Regulatory Compliance (IFAB Law 4 · UEFA Art. 42 · Day 6). Demolding and precision perimeter trimming. Edges are beveled and polished to eliminate sharp edges (an IFAB requirement so the mask is not dangerous to other players). Monochrome finish applied (UEFA Art. 42 compliance). Viscoelastic cushioning foam integrated at the contact areas (cheekbones, frontal bone) along with an adjustable occipital strap system.

07 · Dynamic Test, Final Fit and Delivery (RTP · Day 7). Delivery to the player for a fit test under real conditions: verification of field of vision, absence of ischemic pressure points, breathing and heading test. Minor adjustments if required. Medical clearance to return to training and then to official competition.

Every stage of the process has its evidence. From digital model to finished part.

Return to play (–90%). The traditional recovery protocol without an orthosis can mean up to 71 days out. Our end-to-end workflow compresses the process to 7 days, keeping the player available for the matches that decide a season.

Zero physical iterations (100%). Validation takes place in the digital model. The offloading offset, visual limits and contact geometry are approved before a single part is made, eliminating the cost and time of physical adjustments after manufacturing.

Total personalization (1:1). Every mask is unique. The ±0.1 mm anatomical fit ensures that load distribution during an impact acts exactly where the body can absorb it —cheekbones and frontal bone— protecting the fractured area at all times.