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Fabrication of a Bioactive, PCL-based "Self-fitting" Shape Memory Polymer Scaffold

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Mechanical and Thermo-Regulative Investigations on Additively Manufactured Backpack Pads.

Niko Nagengast¹, Yehuda Weizman¹, Michael Frisch¹

¹Chair of Biomechanics, Faculty of Engineering Science, University of Bayreuth, D-95447 Bayreuth, Germany.

|April 28, 2025

Summary

Additively manufactured backpack pads enhance thermoregulation and comfort during physical activity. These custom lattice structures outperform traditional pads, offering personalized solutions for athletes in demanding environments.

Keywords:

Fused Filament Fabrication (FFF)additive manufacturing extrusion-based 3D printing polymer characterization thermo-mechanical recycling

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Area of Science:

Biomechanics
Materials Science
Sports Engineering

Background:

Backpack pads are critical for comfort and performance in physical activities, especially in demanding environments like mountain sports.
Effective thermoregulation and pressure distribution are essential due to the direct interaction between the athlete's back and the backpack.
Backpack pads act as the crucial interface, influencing heat and moisture management.

Purpose of the Study:

To investigate the mechanical and thermoregulatory properties of backpack pads.
To compare a commercial pad with five additively manufactured lattice structures.
To evaluate the impact of pad design on athlete comfort and performance.

Main Methods:

Utilized additive manufacturing (Large-Volume Filament printing, Multi-Jet Fusion, High-Speed Laser Sintering, Laser Sintering) to create lattice pads.
Assessed pads using standardized mechanical, surface roughness, and humidity tests.
Developed a sensor system (pressure, humidity, temperature) and used thermal imaging for biomechanical testing.
Conducted treadmill tests with 20 male athletes carrying an 8 kg backpack.

Main Results:

Significant athlete preferences were observed for specific pad configurations regarding temperature and humidity management.
Standardized tests corroborated findings on thermoregulation and moisture uptake.
Custom sensor data indicated that damping-improved back plate designs were less critical than pad material and structure.
Additive manufacturing enables personalized backpack pad designs with improved thermal properties.

Conclusions:

Additively manufactured backpack pads offer superior thermoregulation and comfort compared to conventional designs.
Personalized design through additive manufacturing can significantly enhance athlete experience in physically demanding activities.
Future research can focus on optimizing lattice structures for specific user needs and activities.