3D Printed Tennis Racket for Improved Athletic Performance

This project addresses the prevalence of repetitive strain injuries and the lack of customization in modern tennis by developing a modular, 3D-printed carbon fiber racquet with a novel adjustable head-angle mechanism. To overcome the limitations of current fixed-stiffness commercial rackets, the design features a hybrid construction comprising a Markforged Onyx hoop reinforced with continuous carbon fiber, a vibration-damping wooden handle, and aluminum tie rods to bridge critical stress points. Initial Finite Element Analysis (FEA) highlighted the need to thicken early frame profiles to withstand standard string tensions of approximately 55 lbs, leading to an optimized geometry that balances structural integrity with International Tennis Federation (ITF) dimensional standards. Validation is currently proceeding from half-scale geometric prototypes to full-scale static load and impact testing, confirming a sustainable, modular solution where individual subassemblies can be replaced to extend product life and enhance player ergonomics.