Indoor replication of outdoor climbing routes: fidelity analysis of digital manufacturing workflow

This study aims to evaluate the advantages and criticalities of applying additive manufacturing to produce climbing holds replicating real rocky surfaces. A sample of a rocky surface has been reproduced with a budget-friendly 3D scanner exploiting structured light and made in additive manufacturing. The methodology is designed to build a high-fidelity replica of the rocky surface using only minor geometry modifications to convert a 2D triangulated surface into a 3D watertight model optimised for additive manufacturing. In addition, the research uses a novel design and uncertainty estimation approach. The proposed methodology proved capable of replicating a rocky sample with sub-millimetre accuracy, which is more realistic than conventional screw-on plastic holds currently used in climbing gyms. The advantages can be addressed in terms of customisation, manufacturing cost and time reduction that could lead to real outdoor climbing experiences in indoor environments by coupling additive manufacturing techniques and reverse engineering (RE). However, operating the scanner in a rocky environment and the considerable size of the climbing routes suggest that further research is needed to extend the proposed methodology to real case studies. Further analysis should focus on selecting the best material and additive manufacturing technology to produce structural components for climbing environments.