Carbon DLS for Boxing Gear:
the BoxingHandGrenade revolution
BoxingHandGrenade is transforming boxing equipment using Carbon DLS 3D printing technology.
With the collaboration of Prototek, they have pioneered the integration of a 3D-printed grip bar into boxing gloves, a true breakthrough for Carbon DLS sports gear.
From concept to historic firsts
Carbon’s advanced elastomeric resins (EPU series) make it possible to 3D print flexible polyurethane parts with tear strength, resilience, and controlled stiffness comparable to injection-molded elastomers.
In January 2022, BoxingHandGrenade and Prototek launched GhostGrenade-3D Fist-loaders — the first 3D-printed training aids in combat sports built with Carbon’s technology. This was a first in the world for additive manufacturing in boxing.
Building on that, in January 2023 they released GhostGripBar-3D, the first boxing glove to integrate a 3D-printed grip bar created via Carbon DLS. This grip bar uses a Voronoi lattice internal structure to absorb impact, improve punch stability, and enhance structural integrity.
The use of Carbon DLS in sports gear allows not only cutting-edge performance but also design freedom that traditional manufacturing cannot match, especially for integrating lattice structures inside functional components.
Why choose Carbon DLS for sports equipment?
The Carbon DLS (Digital Light Synthesis) process relies on continuous light projection through an oxygen-permeable window, enabling a “dead zone” beneath the curing interface. That allows continuous printing and avoids layer boundaries that weaken parts.
This results in isotropic mechanical properties and highly detailed, smooth-surfaced parts.
Carbon also offers elastomeric materials like EPU 40 / EPU 41 /EPU 43/ EPU 45 / EPU 46, which combine tear strength, energy return, and durability, ideal for impact, vibration absorption, and flexible structural components.
Compared to traditional foam inserts or molded rubber bars, the 3D-printed lattice grip bar can be fine-tuned (e.g. varying wall thickness or cell geometry) to balance stiffness, energy return, and comfort, unlocking a new realm of customization in Carbon DLS sports gear.
Story behind the innovation
Founder John Docherty was inspired during a visit to the Vindolanda museum near Hadrian’s Wall, where he discovered ancient leather handguards (paramani) from the Roman era. That classic form, stripped to its essence, sparked the idea to modernize it with advanced materials and additive manufacturing — leading to GhostGrenade-3D and GhostGripBar-3D.
From Historical Roots to Modern Innovation
Docherty chose Prototek as the technology partner because of their mastery in elastomeric 3D printing and ability to scale from prototype to industrial production. Their combined know-how turned a historical inspiration into a high-tech, high-performance product.
Technical advantages of GhostGripBar-3D
The 3D-printed bar design incorporates a Voronoi lattice or other advanced geometries to:
Absorb high-velocity impacts with controlled deformation
Enhance wrist-hand alignment and punch stability
Improve structural integrity with tailored stiffness
Minimize bulk and weight better than traditional alternatives
Compared to standard foam or molded bars, the GhostGripBar-3D promises superior mechanical performance, comfort, and durability.
Expanding the frontier: more applications ahead
The success of GhostGripBar-3D has inspired broader adoption of Carbon DLS sports gear applications: helmets, mouthguards, impact paddles, technical boots, internal glove padding, and shock shields.
Also in development are leather knuckle protections with 3D lattice structures inspired by Roman design.
Prototek supports the entire lifecycle from design to serial production, leveraging Carbon’s 3D elastomeric capabilities to deliver bespoke, high-performance sports components.
How you can adopt this Carbon DLS technology
If you’re developing impact-resistant sports equipment or performance gear, Carbon DLS opens unprecedented opportunities:
Prototype your lattice structures with variable stiffness, porosity, and geometry.
Simulate your designs to balance energy absorption, weight, and durability.
Use Prototek or a Carbon DLS bureau to produce functional prototypes or pilot runs.
Iterate and test under real-world conditions before scaling.
Prototek: from concept to mass production.
With deep expertise in advanced elastomeric 3D printing, Prototek has overseen the entire development of BoxingHandGrenade products, from prototyping to industrial manufacturing.
The combination of advanced materials, intelligent design, and Carbon 3D technology has made it possible to turn a historical intuition into a highly technical product, ready to meet the challenges of modern sports.
Contact Prototek for consultancy and guidance. Our Experts will help you harness Carbon DLS capabilities, from design optimization to industrial output.
