In recent developments, 3D printing company Carbon has announced a groundbreaking innovation: the ability to produce intricate and diverse lattice structures from a wide range of elastomeric materials. This advancement could significantly impact or even disrupt the traditional foam industry, which has long relied on conventional materials for comfort, safety, and performance applications.
Carbon has introduced a new lattice solution that streamlines the design process. Users simply input the required specifications—such as weight, size, and mechanical properties—into the Carbon software, and the system automatically suggests the most suitable grid structure and material. This not only simplifies the design workflow but also allows for highly customized solutions tailored to specific needs.
The open-cell nature of 3D-printed lattices offers breathability, a key advantage over traditional foams, which often suffer from poor airflow. Additionally, these structures can be engineered with adjustable compression profiles, enabling enhanced comfort across different applications. Designers can fine-tune the mesh geometry and metamaterials to achieve varying levels of softness or firmness, making them ideal for use in products like headphones, seating systems, and orthopedic supports.
When it comes to safety, Carbon highlights the potential of its 3D-printed grids to replace traditional foam-based shock-absorbing materials, such as expanded polystyrene (EPS) used in helmets and car seats. The lattice structures can offer comparable impact absorption while providing greater flexibility in design. This makes it possible to create custom protective gear for athletes or specialized users, enhancing both fit and performance.
Moreover, Carbon’s technology enables the creation of monolithic components that integrate multiple functional areas within a single part. Unlike foam-based products that often require assembly of numerous components, 3D-printed lattices allow for seamless integration of different densities and mechanical properties in one piece.
One of the most visible applications of this technology is in performance-oriented products, such as sports equipment and footwear. Carbon has partnered with Adidas to bring its Futurecraft 4D shoes into mass production. These shoes feature a midsole with tailored lattice structures in the heel and forefoot, offering optimized cushioning during movement. This level of customization marks a significant step forward in the evolution of functional footwear.
With innovations like Futurecraft 4D, Carbon is not just pushing the boundaries of 3D printing—it's redefining how we think about comfort, safety, and performance in everyday products.
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