Objective

The objective of this project was to design a high-performance lacrosse head, tailored to meet the demands of competitive gameplay. The design needed to balance strength, flexibility, and lightweight construction while ensuring compliance with official lacrosse standards. Additionally, the lacrosse head had to accommodate precise control for catching, carrying, and throwing the ball during intense gameplay.

1. Concept Development

The project began with a thorough understanding of the sport of lacrosse, focusing on player needs and game demands. Insights were gathered by analyzing existing lacrosse head designs, reviewing competitor products, and engaging with players to identify pain points and desired improvements. Key objectives identified were:

• Structural Integrity: The head must withstand impacts and rough usage while maintaining its shape.

• Flexibility & Stiffness Balance: The frame should be flexible enough for ball control yet stiff enough for accurate passing and shooting.

• Lightweight Design: Reducing weight to minimize player fatigue.

• Aerodynamic Efficiency: The shape should reduce drag during motion.

Through these insights, the initial sketches focused on incorporating structural ribbing for durability, a streamlined shape for aerodynamics, and a strategic hole pattern for weight reduction. The concepts were shared with the client, and feedback guided the final design direction.

2. Sketching & Initial Approval

The initial hand sketches included three variations of the lacrosse head frame. These concepts explored different geometries for the sidewalls and scoop, emphasizing the following features:

• Sidewall Design: Open areas with triangular ribbing for reduced weight and added strength.

• Scoop Shape: A slightly curved scoop for efficient ground ball pickups.

• Throat Area: A reinforced yet lightweight design to connect to the lacrosse shaft securely.

After presenting the concepts, the client selected a design that best aligned with their vision. Minor adjustments were suggested, such as optimizing the hole placements for better stringing options and refining the scoop curve for better ball retention.

3. 3D CAD Modeling

Using SolidWorks, the finalized sketch was transformed into a detailed 3D model. This phase involved:

a. Structural Design

The frame featured a triangular rib structure, providing enhanced strength in high-stress areas while maintaining flexibility. The open sidewalls reduced weight without sacrificing durability.

b. Hole Pattern Optimization

The stringing holes were strategically placed along the perimeter to give players maximum customization for stringing pocket depths and styles.

c. Scoop Design

The scoop curvature was refined for seamless ground ball pickups, ensuring smooth motion without catching on uneven surfaces.

d. Throat Geometry

The throat area was reinforced for a secure attachment to the shaft while minimizing unnecessary bulk.

During this stage, FEA (Finite Element Analysis) simulations were conducted to identify stress concentrations. Adjustments were made to redistribute stress evenly, particularly in the sidewalls and throat area.

4. Prototyping

The initial prototypes were 3D printed using SLA technology for precise detailing. The material used was a durable resin, mimicking the final product's structural properties. Prototypes were subjected to:

• Impact Testing: Simulated high-impact collisions with other lacrosse heads and balls.

• Flexibility Tests: Ensured the frame could bend under pressure without breaking or deforming.

• Field Testing: Local players tested the prototypes to assess handling, stringing ease, and overall performance.

Feedback revealed that the prototype performed well in handling and strength but required minor tweaks to the throat geometry for a tighter fit on the shaft. The scoop also needed slight reshaping to improve ground ball pickup efficiency.

5. Testing & Refinement

Based on feedback, the design was further refined:

• Throat Fit Adjustment: The throat connection was modified to achieve a more secure attachment.

• Material Selection: For production, nylon reinforced with glass fibers was chosen, offering a balance of strength, flexibility, and lightweight performance.

• Hole Placement Fine-Tuning: Adjustments were made to accommodate more stringing options, enhancing customization for players.

• Weight Reduction: Additional material was removed in low-stress areas without compromising strength, reducing the overall weight further.

A second round of prototypes incorporated these changes and underwent additional testing. The results showed marked improvement, confirming the design’s readiness for production.

6. Final Design and Manufacturing Handoff

The final design was approved, and detailed 2D technical drawings and 3D files (STEP and STL formats) were prepared for manufacturing. The technical package included:

• Dimensions and Tolerances: Precise specifications for each part of the head.

• Material Recommendations: Nylon with 30% glass fiber for injection molding, ensuring strength and durability.

• Stringing Guide: A user-friendly diagram showing optimal stringing patterns for the head.

The manufacturing handoff also included suggested mold flow analysis to ensure proper material distribution during injection molding.