In this episode, we unpack how a college capstone project turned into a scalable system for custom-fit 3D-printed bracing, moving from “hours in CAD” to minutes with automated design templates. We get into the origin story, the technology moat, go-to-market evolution, fundraising, and the founder mindset required to stay in the game.

Highlights covered

• How PROTECT3D started with a custom brace for a Duke teammate
• Why “one-size-fits-none” is the real problem in bracing
• The core workflow: iPhone scan → automated digital design → 3D print
• How they reduced design time from 5+ hours to under 5 minutes
• Material/printing approaches and why they use multiple technologies
• Scaling from sports to insurance-reimbursable clinical products
• Expansion into military / defense applications via non-dilutive funding
• Founder lessons: failing fast, surviving COVID-era building, and grit
• Kevin’s advice to younger founders: keep going, the grind is the game

Custom-fit should be the norm, and PROTECT3D is building the rails to make that possible at scale. If you’re a founder working at the intersection of software + real-world manufacturing, this one is packed with practical lessons and a lot of heart.

Timestamps:
00:04:29 — Kevin’s background: Greensboro → Duke mechanical engineering + football

00:05:43 — The spark: 3D-printing a custom brace for an injured teammate

00:06:37 — “One-size-fits-none”: why off-the-shelf bracing fails most bodies

00:10:23 — Turning it into a real company through Duke I&E + early traction

00:12:21 — Early funding: friends & family + NC IDEA Micro Grant path

00:16:45 — The modern 3-step process: app scan → digital fabrication → 3D print

00:17:11 — From traveling to scan athletes… to scanning with an iPhone app

00:23:29 — Scaling breakthrough: design time drops from 5+ hours to <5 minutes

00:24:19 — Growth: working with over half of NFL teams + other leagues

00:25:21 — Beyond sports: clinics, insurance reimbursement, nationwide footprint

00:32:44 — Fundraising + non-dilutive: ~$5.5M raised, including DoD/SBIR support

00:34:44 — Founder lessons: fail fast, market expansion timing, surviving COVID

00:36:25 — Team size: 12 FTE + ~5 contractors; vision for clinical-scale bracing

00:38:30 — New channel: “at-home” scanning + direct-to-consumer experiments

00:41:18 — Kevin’s message to young founders: keep at it, the grind doesn’t stop

Where to Find Kevin Gehsmann:
LinkedIn: https://www.linkedin.com/in/kevin-gehsmann/
Front PROTECT3D: https://protect3d.io/

Where to Find Scot Wingo:
LinkedIn: https://www.linkedin.com/in/thescotwingo/
Tweener Times: https://www.tweenertimes.com/
X: https://x.com/scotwingo

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This episode of Triangle Tweener Talks is hosted by Scot Wingo, presented and produced by Triangle Tweener Fund, with creative assets and design support from Walk West.

We couldn’t share posts like this without our amazing sponsors:

Platinum:
NC IDEA: https://ncidea.org

Gold Sponsors:
- Balentine: https://www.balentine.com/triangle-entrepreneurs
- EisnerAmpner: https://www.eisneramper.com
- Robinson Bradshaw: https://www.robinsonbradshaw.com

Silver Sponsors:
- Automated Consulting Group: https://automated.co
- Bank of America: https://business.bofa.com/en-us/content/technology-industry-group.html

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Triangle Tweener Talks is sponsored by:

• Atomic Object: https://atomicobject.com/