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/