Can 3D-Printed Helmet Inserts Revolutionize Communication for Football Players? Michigan State University Thinks So

At Michigan State University (MSU), a groundbreaking project led by Tamara Reid Bush, associate professor of mechanical and biomedical engineering, and student Rylie DuBois could change football forever. Their innovation? 3D-printed helmet inserts designed to block crowd noise and enhance on-field communication.

This cutting-edge technology aims to help players hear their coaches’ calls more clearly, a challenge in stadiums roaring with fans. Could this be the solution football teams have been waiting for?

Why These Helmet Inserts Matter
Football players often struggle to hear sideline calls over the deafening noise of a stadium. The MSU team focused on solving this issue. Their helmet inserts snap securely into earholes, muffling external sounds while allowing critical communication.

The inserts were extensively tested with feedback from MSU football players, ensuring they stayed firmly in place during tackles and high-pressure moments. The result? A game-changing improvement in player focus and coordination.

Challenges of the Innovation
Developing these inserts wasn’t simple. Helmets vary in earhole size and design, requiring the team to create custom fits for each model. Using durable, 3D-printed plastic, they overcame these challenges, creating a flexible, secure design that works across multiple helmet brands.

What Players Are Saying
Athletes who tested the inserts reported a noticeable difference in communication on the field. Instead of battling crowd noise, they could focus on their game.

DuBois, a student engineer, described the project as an inspiring experience. Spotting quarterback Aidan Chiles wearing the inserts during a game was a highlight of her career, showcasing the real-world impact of her design.

A Win for Education and Innovation
This project highlights MSU’s commitment to blending academics with practical applications. For DuBois, it was more than just a design exercise—it was a lesson in teamwork, problem-solving, and engineering creativity. She expressed pride in contributing to a tool that could transform athletic performance.

A Glimpse Into the Future of Sports Technology
The MSU team’s success sparks exciting questions about the future of sports gear. Could customizable helmet inserts become standard equipment for football teams worldwide?

For now, MSU’s innovation shows how engineering can directly impact athletics, giving players tools to overcome challenges like crowd noise.