In sports, injuries are part of the game. But the recovery process shouldn’t mean sitting out longer than necessary. For athletes, every day off the court feels like a setback. For athletic trainers and other medical personnel, the challenge is helping their athletes return to play safely, without compromising protection, performance, or confidence.
At PROTECT3D, we believe innovation should make recovery smarter and faster. Our work in 3D-printed facial protection isn’t just about creating custom masks. It’s about rethinking what’s possible in athlete care by combining precision technology with clinician expertise.
Bridging Innovation and Care
Traditional hand-molded facemasks have served their purpose for years, but they come with limitations: inconsistent fits, long turnaround times, and extremely high prices (oftentimes in the thousands).
On the other hand, off-the-shelf, non-custom facemasks just don’t get the job done. They have poor fit, poor visibility, and don’t allow athletes to compete confidently. Don’t settle for something you can buy for less than $100 online.
Using advanced 3D scanning and additive manufacturing, PROTECT3D’s process creates facemasks that mirror an athlete’s exact anatomy and injury profile. The result is a lightweight, form-fitting solution designed to protect without restricting play.
Every mask is:
- Anatomically accurate, ensuring comfort and clear vision during performance.
- Lightweight yet durable, using advanced biomaterials to balance flexibility and strength.
- Tailored to the individual, addressing their specific injury and performance requirements.
This approach represents a shift from one-size-fits-all protection to personalized recovery solutions, driven by both science and compassion.
Trusted by Leading Teams and Clinicians
Across professional and collegiate sports, PROTECT3D’s custom facemasks have become the standard of care solution for getting athletes back in the game.
Athletes such as Jaylen Brown (NBA), Bradley Beal (NBA), and Diego Luna (MLS, Real Salt Lake / USMNT) have relied on PROTECT3D technology to get back in the game with confidence.
Watch Video: Real Salt Lake Medical Staff Uses PROTECT3D to Help USMNT Star Diego Luna Get Back on the Pitch
Behind every success story is a team of healthcare professionals using technology to enhance care, not replace it. That partnership is what makes this innovation meaningful.
Streamlining the Clinical Workflow
For medical professionals, time and accuracy are everything. PROTECT3D’s digital workflow is designed to make their jobs easier while improving outcomes for patients.
- Scan: Capture the athlete’s facial structure in minutes using secure iPhone scanning tools.
- Collaborate: Work directly with PROTECT3D engineers to refine design and fit.
- Print and Deliver: Receive a precise, ready-to-wear facemask within days.
By removing the need for manual molding and modification, clinicians can focus more on patient care and less on production logistics. The process is simple, efficient, and built around their expertise.
What Clinicians Are Saying
“PROTECT3D’s facemasks are lighter, lower profile, and better fitting than any other available options, and the design quality is impossible to achieve with traditional hand-molded masks. The most important thing for me is getting guys back to play as safely and quickly as possible, and this allows me to do that with something guys are actually excited to wear.”
Jose Fonseca
Duke Head Men’s Basketball Athletic Trainer
“Incorporation of three dimensional scanning and immediate fabrication of anatomically specific patient protective devices literally has become a game changer for competitive and recreational athletes alike. The utilization of biomaterials for face mask fabrication affords greater strength, decreased weight, lower profile and ultimately more protection than currently available materials. The lower profile and greater strength and protection allow world class athletes to return to the highest level of competition with minimal impact on their performance, with the security the device will prevent additional injury.”
Dr. David B. Powers, MD, DMD, FACS, FRCS (Ed)
Director, Duke Health Craniomaxillofacial Trauma Program
These insights highlight a larger shift in the field: precision manufacturing is becoming an essential part of modern sports medicine.
Making Advanced Care More Accessible
While PROTECT3D technology has been used at the highest levels of competition, it’s now becoming more accessible for clinics, schools, and independent athletes.
- Clinicians and athletic trainers can integrate the PROTECT3D Platform directly into their workflow to scan, order, and deliver facemasks faster.
- Athletes and parents can use the PROTECT3D App to securely capture a 3D scan and receive a professional-grade mask at their door in days.
It’s the same technology used by elite teams, adapted for every level of play, and at a price point that won’t break the bank.
A Glimpse Into the Future
What started with elite sports protection has expanded into a broader movement toward personalized orthotic and protective solutions. The same 3D scanning & printing methods used for PROTECT3D Facemasks are being applied to AFOs, fracture casting, and a whole suite of bracing and support products. Around the industry, similar technology is being used to make personalized orthopedic joint implants that are 3D printed in Titanium Alloy based on a CT scan of your bones.
For clinicians, that means faster, more consistent results. For athletes, it means a safer, more confident return to sport. For everyday patients, it means a better, overall improved quality of life.
At PROTECT3D, we’re not just changing how protection looks; we’re redefining what it means to care for the modern athlete. Personalized medicine is the future.