For my final year Product Design Engineering project, I knew I wanted to create something related to sport. Having played various sports throughout my life, I’ve always disliked shin guards—they rub, never fit properly, and feel like an inadequate solution. However, after speaking with female athletes, I realized that my frustrations were minor compared to the challenges they faced when wearing shin guards.
Through focus group sessions with both professional and amateur female athletes, two main issues became clear: poor fit and a lack of breathability in current shin guards. Identifying these as my key problems to solve, I structured my design process around them.
Fit
To improve fit, I took an iterative design approach, involving continuous testing and refinement with users. Using the Form Environment in Fusion 360, I designed an initial shape, which was then 3D printed and tested by athletes. Their feedback guided each redesign, and after seven iterations, I arrived at a form that met my requirements for comfort and usability.
Breathability
My work on breathability focused on material selection and strategic vent placement. I prioritized low-density materials with high thermal conductivity to enhance heat transfer, which has been highly successful so far. Additionally, I conducted infrared scanning to identify areas of high heat buildup. This data informed the placement of uniquely designed vents in the foam, allowing heat to dissipate effectively. These vents not only improve performance but also contribute to the product’s aesthetic.
Sustainability & Safety
To ensure sustainability, I designed the shin guard without adhesives, making it easier to recycle and improving its washability. I also conducted FEA simulations and physical testing to verify that the product meets shin guard safety standards, ensuring reliable protection for users.
I've thoroughly enjoyed this project so far, and with a few final refinements, I’m hopeful for a successful outcome.
I can’t thank the RS Student Fund enough for their support—it has allowed me to tackle this problem more efficiently and explore innovative solutions!
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