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NFL Ready Fitness Product Created With 3D Printing

3D Printing for Sports Recovery

Using 3D Printing to Bring Preventative Treatment to the NFL From Early-Stage Design to Tooling in Eight Weeks

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Recoup Fitness has created a simple, yet powerful, tool to aid athletes in recovery from all injuries, from the most critical health issues to normal in-game bumps and bruises. Recoup’s founders, with backgrounds in college athletics, saw a serious lack of accessible methods of personal preventative treatment across the sports landscape.

To address this need, CEO Matt Hyder and his business partner Jeffrey Ballard came up with an early concept for “The Stinger,” a cold massage roller for the upper and lower body. The product is especially useful for rehabilitation and post-workout treatments to aid the body’s recovery from exertion and strenuous physical activity. Designed to ice and reduce inflammation while releasing tension through pressured massage, the Stinger allows athletes from amateur to pro to quickly and easily recover.

Concept Development

Working with Fathom’s Seattle team, Recoup was able to iterate rapidly, tweaking and improving their design incrementally and design for manufacture through Fathom’s manufacturing expertise.


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Project Highlights—

  • 3D printed parts for early iterations, provided product design consulting services and DFM feedback for optimizing and validating the product
  • Used room temperature vulcanization to mold cosmetic show models for marketing purposes
  • Produced set of RTV molded parts in customized colors to cater to professional sports teams
  • Recoup moved to production with injection molded tools. While Fathom was in the middle of the tool build process, Recoup Fitness discovered a tolerance issue with the mating parts of their product from another supplier. Forced to act quickly and initiate non-steel safe tool modifications, Fathom validated the tool adjustments through 3D printed parts to build confidence with the fitment of their mating parts ahead of the production volume order
  • Working against a compressed schedule, the production part order was completed, shipped and Recoup was shipping their product within days of receiving the finished parts

Through Fathom, Recoup went from early-stage design to tooling in eight weeks.

Early Adopters

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Early adopters of the Stinger include individual NFL athletes, entire NFL training staffs and international soccer players.

Kenny Anunike, NFL Defensive End for the Super Bowl Champion Denver Broncos, attests to the Stinger’s power: “As a professional football player, my body is constantly taking the highest level of punishment and the demand for quick, effective recovery is essential. These guys have seen a need and created the most effective, low-maintenance recovery tool I have ever used.

Learn more about Recoup Fitness and the Stinger at the Recoup website: recoupfitness.com.

To read more about accelerated product development with Fathom, check out other blog posts documenting our work with womens health startup NextGen Jane, mobile charging company Doblet and phone-based virtual reality company Figment VR.

Have a project that could use a boost? Start a conversation with us today!

Comprehensive Capabilities for Rapid Manufacturing

At Fathom we offer a unique advantage of speed and agility-our experts help companies go from concept to prototype to manufacturing in ways not previously possible. 

90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day
   

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30 Second Quotes
Prototype Tool / / As soon as 10 days
10K Parts / / 10 days
Production Tool / / As soon as 3 weeks
 

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3 & 5 Axis Milling & Turning
(Plastics, Composites and Metals)

Tolerance Accuracy Range
from +/-0.001″ to 0.005″

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Injection Molding Adjacent
without High Costs of Metal Tools

Most Commonly Used for High-Volume
Prototyping & Bridge to Production

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Finishing, Production Painting and Color Matching

Assembling, Including Embedded Electronic
Components, Threaded Inserts, and More

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CAD, DFAM and DFM Services

Apply Methods to Increase Speed
and Decrease Total Cost

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Highly Trained Staff / / Full-Time & Part-Time
Support as Short-Term & Long-Term Strategy

Decrease Downtime with Customizable
Staffing Accelerates Implementation

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Let’s get started.

Fathom is driven by advanced technologies and methods that enhance and accelerate today’s product development and production processes.

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Manufacturing Locations Across National Time Zones
Manufacturing Locations Across National Time Zones
The Fathom Advanced Manufacturing Platform
new map update 3
HEADQUARTERS

1050 Walnut Ridge Drive
Hartland, WI 53029
ISO 9001:2015
AS9100:2016
ITAR

ARIZONA

444 W. 21st St. Ste. 101
Tempe, AZ 85282
ISO 9001:2015
NIST800-171 Compliant
ITAR

COLORADO

7770 Washington St.
Denver, CO 80229
ISO 9001:2015
ITAR

MINNESOTA

13758 Johnson Street NE
Ham Lake, MN 55304

TEXAS

1801 Rowe Lane
Pflugerville, TX 78660
ISO 9001:2015
AS9100:2016

1513 Sam Bass Rd
Round Rock, TX 78681
ISO 9001:2015
ISO 13485:2016

CALIFORNIA

620 3rd Street
Oakland, CA 94607
ISO 9001:2015 Design Certified
NIST 800-171 Compliant
ITAR

FLORIDA

14000 N.W. 58th Court
Miami Lakes, FL 33014
ISO 9001:2015 Design Certified
ISO 13485:2016


 

NEW YORK

1920 Slaterville Rd
Ithaca, NY 14850
ITAR

401 W. Shore Blvd.
Newark, NY 14513
AS9100:2016
ISO 9001:2015
ITAR

ILLINOIS

1207 Adams Drive
McHenry, IL 60051

1401 Brummel Ave
Elk Grove, IL 60007
ISO 9001:2015 Design Certified