Ex-Duke Footballers 3D-Print Custom Braces for Athletes

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February 4, 2026 Applications 10355

Former Duke University Football Players 3D Print Custom Braces for Recovering Athletes

In 2019, Kevin Gehsmann, Clark Bulleit, and Tim Skapek co-founded PROTECT3D, a company that is leveraging 3D printing to revolutionize sports medicine. The custom braces developed by these former Duke University football players are designed to help athletes recover and return to the field faster, and have now become a standard solution in professional sports. It all started back in their college days, when Gehsmann, a mechanical engineering graduate, and his two co-founders combined their knowledge of biomechanics, passion for sports, and 3D printing technology to assist their former teammate Daniel Jones, who is now a quarterback for the Indianapolis Colts. Today, this North Carolina-based company uses 3D printing to manufacture a wide range of products, from orthotics and braces to splints, arm casts, thumb guards, and even impact protection pads.

Medical staff perform 3D scans of their patients using a smartphone. PROTECT3D then utilizes this scan data to create a digital design. Within about 48 hours, a custom brace is 3D printed and shipped, enabling athletes across the United States to return to the field for mid-week training sessions. The company aims to expand its reach to assist military personnel and broader communities.

"The best part about creating custom products for people is the tangible impact they have—like a lower limb, ankle, or foot orthosis that helps people walk better than they have in years," said CEO Gehsmann.