COMPONENT DESIGN FOR ASSEMBLY
After the final concept presentation, MWDesign will focus on the approved product concept. This will be done primarily through 3D CAD modelling. We will further development the CAD models into precise components incorporating all features from the final concept design. The objective is to develop the design to allow us to create a prototype for testing, before investing in tooling.
Focusing on individual part components, MWDesign will refine the components and design out the cost to enable us to maintain quality while meeting our budget cost. We will begin engineering the parts for the product, focusing on functional aspects of the design.
COMPONENT DESIGN FOR ASSEMBLY
After the final concept presentation, MWDesign will focus on the approved product concept. This will be done primarily through 3D CAD modelling. We will further development the CAD models into precise components incorporating all features from the final concept design. The objective is to develop the design to allow us to create a prototype for testing, before investing in tooling.
Focusing on individual part components, MWDesign will refine the components and design out the cost to enable us to maintain quality while meeting our budget cost. We will begin engineering the parts for the product, focusing on functional aspects of the design.
COMPONENT DESIGN FOR ASSEMBLY
After the final concept presentation, MWDesign will focus on the approved product concept. This will be done primarily through 3D CAD modelling. We will further development the CAD models into precise components incorporating all features from the final concept design. The objective is to develop the design to allow us to create a prototype for testing, before investing in tooling.
Focusing on individual part components, MWDesign will refine the components and design out the cost to enable us to maintain quality while meeting our budget cost. We will begin engineering the parts for the product, focusing on functional aspects of the design.
Max Darling
Protective Face Mask
Custom-built for New Zealand Breakers forward Max Darling following an orbital fracture, this personalised 3D-printed protective mask enabled a safe return to professional basketball. Combining precision scanning, ergonomic design, and rapid manufacturing, the project showcases the potential of bespoke sports protection tailored to
the individual athlete.
SERVICES
Industrial Design
3D Scanning
CAD Development
Visual Renders
Prototyping
OPPORTUNITY
Back On The Court
When New Zealand Breakers forward and Tall Black Max Darling suffered an orbital fracture during training, his recovery presented a unique challenge. While surgery repaired the injury, returning to professional basketball required a protective face mask that could safely shield the affected area without compromising comfort, vision, or performance. With no suitable off-the-shelf solution available, the opportunity emerged to create a fully customised piece of protective equipment tailored specifically to the athlete.
"Firstly, no-one knew how to do it, and, secondly, it was December 24th and New Zealand had closed down. But up stepped Mike and his team from MWDesign in Hamilton to create one of the genuinely coolest, most comfortable, and most protective masks I have seen to get Max safely back on the court following his eye socket fracture."
- Breakers physiotherapist Rob Knight
APPROACH & OUTCOME
Precision Under Pressure
Working closely with Knight and Darling, MWDesign rapidly developed a bespoke solution using advanced digital design and manufacturing techniques. A high-resolution laser scan of Darling's face captured the exact contours of his anatomy, allowing the team to design a protective structure precisely around the injury site while minimising bulk and weight. Unlike generic sports masks, the solution was custom fitted to the athlete, delivering a secure and comfortable fit capable of withstanding the demands of professional basketball.
The design process extended well beyond impact protection. Careful consideration was given to comfort, visibility, ventilation, stability, and appearance. Multiple iterations were evaluated to optimise material thickness, facial contact points, and the retention system, ensuring the mask remained secure during high-intensity play. Integrated sweat-management features further improved comfort and helped maintain clear vision during competition.
Manufactured from a glass-reinforced 3D-printed composite, the final mask combined strength, light weight, and rapid production. Delivered within days during the Christmas shutdown period, the project demonstrated how digital design, 3D scanning, and additive manufacturing can solve complex
problems at speed.