Bobsledders use 3D-printed footwear and AI for 2026 Olympics

Bobsled teams use 3D printing and AI

Bobsledders competing in the 2026 Milano Cortina Winter Games are deploying 3D-printed footwear and AI-driven trajectory modeling to gain a competitive edge. These technologies target the three critical phases of a race: the initial push, technical driving through curves, and final braking.

Athletes on the 1.5-kilometer track reach speeds of 145 kilometers per hour. During these descents, crews experience gravitational forces exceeding 5g. Precision in equipment design has become the primary way for teams to shave hundredths of a second off their times.

The sport has transitioned from wooden sleds in 1924 to modern carbon fiber shells. While the materials have changed, strict regulations govern the size and weight of every sled. These rules ensure that technical innovation does not bypass the physical requirements of the athletes.

Weight limits define sled design

The International Bobsleigh and Skeleton Federation enforces specific weight and length maximums for every competition class. A two-person bobsled cannot exceed 2.7 meters in length. The total weight, including the crew and their gear, must stay under 390 kilograms.

Four-person teams face a weight cap of 630 kilograms. Their sleds are limited to 3.8 meters in length. These constraints prevent teams from simply hiring the heaviest possible athletes to increase downhill momentum.

Because weight is equalized, the "push" phase at the start of the race is often the most decisive factor. This 30-to-50-meter sprint determines the sled’s initial acceleration. Engineers now focus heavily on the interaction between the athlete’s feet and the ice.

BMW prints custom spikes for Germany

German athletes won 16 of their 27 medals in sliding sports during the 2022 Beijing Games. To maintain this dominance, the German federation partnered with BMW to redesign athletic footwear. The automaker uses 3D printing to create custom spike plates for individual team members.

These plates integrate directly into the bobsledders' shoes to provide maximum traction on the ice. 3D printing allows BMW to adjust the stiffness and shape of the studs based on an athlete's specific running style. This manufacturing method also lets engineers test and iterate on new designs in days rather than months.

BMW uses a process called plasma nitriding to harden the steel spikes. In a high-temperature vacuum, ionized nitrogen diffuses into the metal surface. This treatment prevents the spikes from breaking or wearing down during the high-torque start of the race.

US teams adopt carbon fiber insoles

The US Bobsleigh and Skeleton Federation is using specialized dynamic insoles to improve energy transfer. Developed by VKTRY Gear, these insoles are made of aerospace-grade carbon fiber. Unlike standard foam inserts, these devices are designed to return energy to the athlete.

Founder Matt Arciuolo designed the insoles with a specific curve that only touches the ground at the heel and toe. When an athlete pushes against the ice, the carbon fiber plate flexes and then snaps back. This mechanical advantage helps bobsledders maintain higher speeds during the sprint phase.

Gold medalist Kaillie Humphries uses this tech to optimize her monobob performance. The added stiffness in the footwear ensures that no energy is lost to shoe deformation. Every ounce of force generated by the athlete goes directly into moving the sled forward.

AI models the perfect trajectory

The US team has partnered with Snowflake to use AI tools for performance analysis. These algorithms analyze data from hundreds of practice runs to identify the most efficient crew pairings. The AI looks for tiny inefficiencies in how athletes move together during the "jump" phase.

The jump occurs when the athletes stop running and board the moving sled. Any bumping or misalignment during this transition creates drag and loses time. Snowflake’s software identifies these physical collisions so coaches can adjust the timing of each athlete's entry.

Germany uses a competing system called Data Coach. Developed by former luge champion Julian von Schleinitz, the system uses sensors mounted directly on the sled. These sensors track the sled's path through every curve of the Cortina Sliding Centre.

• Accelerometers measure the force of every turn.
• Gyroscopes track the rotation and tilt of the sled.
• GPS mapping correlates speed with specific track coordinates.
• AI models suggest the ideal line to minimize friction against the ice walls.

Aerospace materials increase sled safety

China has developed a new sled using T800 carbon fiber. This composite material is more commonly found in aerospace engineering due to its high rigidity. The new design reduces the weight of the sled shell by 20 percent compared to older models.

This weight reduction allows teams to redistribute ballast lower in the sled. A lower center of gravity makes the bobsled more stable and less likely to flip during high-speed turns. The T800 fiber also offers better impact resistance during collisions.

Safety remains a primary concern as sleds approach 90 mph. High-speed crashes can cause severe injuries to the neck and spine. Engineers are now balancing the pursuit of speed with new structural reinforcements.

Allianz develops the Safety Sled

The German federation and Allianz recently introduced the Safety Sled prototype. This vehicle acts as a mobile laboratory to analyze ice conditions before races. It also features new hardware designed to protect athletes during rollovers.

One primary feature is the Head Impact Protector. This frame integrates into the sled without blocking the athletes as they jump inside. It provides a roll-cage effect that keeps the riders' heads away from the ice if the sled flips over.

The sled also features raised push bars at the rear. These bars create a larger survival space for the athletes in the back of the sled. Carsten Reinkemeyer of the Allianz Center for Technology stated the goal is to keep athletes inside the sled during any accident.

Current safety research includes the following priorities:

• Retention systems to prevent athletes from being ejected during a roll.
• Enhanced braking mechanisms for emergency stops.
• Protective suits with integrated padding for high-force impacts.
• Helmet upgrades designed for the specific vibration frequencies of bobsledding.

The Institute for Research and Development of Sports Equipment in Berlin is currently testing these systems. They are developing a two-part safety suit that connects to the sled's interior. This setup aims to stabilize the athlete’s body against high collision forces and prevent internal injuries.