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Baseball bats with a custom shaped handle

DeskProto generates the CNC data in an automated process


Two hands holding a baseball bat
The ergonomic shape of the handle fits the hand like a glove.

Rayline Baseball (USA) has set up a production line for baseball bats with an ergonomic shaped custom handle. The photo shows such handle, matching the shape of the hand for optimal grip.

Currently the handle's shape is a generalized model, comfortable for most users. The shape can be scaled +/-10% along the X-axis to accommodate different hand sizes. Really bespoke handles will be available soon, based on a 3D scan of a clay imprint made by the client's hands.


Animation of the toolpath in DeskProto: one long helix over the complete bat.

Though the geometry to be machined has a complex freeform shape, for DeskProto it is an easy job to calculate the toolpath. This is one long helix type toolpath to CNC machine the complete baseball bat, using a machine with a rotation axis.

Even with the “generalized” handle geometry there are over 60 variations of baseball bats. Length, barrel diameter, handle size, and handedness create all of these variants. Each of the variants will use the exact same CNC strategy, which means that the process of calculating the CNC toolpaths can be automated.

The geometry is modelled in the Solidworks CAD software, and a macro is used to export the resulting bat variant as STL file . Each STL file is aligned to same coordinate system. Next, in DeskProto a script and a template project are used to generate the NC file, completely automatic.

This type of DeskProto automation is quite common for medical applications, like braces, prosthetics and orthotic insoles. See the medical Gallery projects. In all cases the application is about custom variants of one product, where the same CNC settings can be used for all variants.


The custom made CNC machine removes material at a very high speed.

The CNC machine has been specially designed for this application, and has been built in-house. It is a 4-axis CNC machine - though only 3 axes are truly necessary (X,A,Z). It is a very powerful machine, capable of machining the bats at a very high speed.

The cutter is quite large: a 1/2 inch diameter ballnose end mill. This results in a very smooth surface: only a little manual sanding is needed to finish each bat.


Two baseball bats, completely finished.
Two bats, with completely different handle shapes.

The developments in CAD and CAM make more and more bespoke products affordable: unique products, custom made for just one client.

When you are interested in these baseball bats please contact Rayline Baseball. When you are interested in automating your application you can of course contact the DeskProto support team.