Custom-made mask protects Danilo during recovery process

Approximately one month ago, on October 11, defender Danilo suffered a serious facial injury following a collision with Fluminense goalkeeper Fábio. The Rubro-Negro player was taken directly from the Maracanã to hospital. The following day (12), he underwent surgery conducted by Gustavo Machado, a bucomaxillofacial surgeon from Flamengo's dental department, and his team. The procedure also involved orthopaedist Fernando Sassaki, cardiologist Luiz Macedo, and Guto Ferreira, coordinator of the dental department.

With two fractures to his jaw, Danilo received four plates and 20 screws. In many cases, this would be reason enough to end the season. Not for Danilo, whose excellent health and determination have proven invaluable. Since November 9, the defender has been conducting on-pitch training sessions with other players. To make this possible, he wears a protective mask produced by the club under the supervision of coordinator Guto Ferreira.

"I started using the mask when I returned to training at the academy on November 2 to get accustomed to it. The biggest challenge was adapting my breathing. The mask keeps the mouth more closed, but now I'm used to it," the player said.

The process of creating the facial protector began with a detailed analysis of the trauma, considering the type and location of the injury, as well as imaging exams. From this information, a personalised plan was developed that took into account the athlete's physical characteristics, the regions requiring protection, and the demands of football.

With the aid of digital technologies, such as facial scanning, it was possible to replicate the athlete's facial anatomy and develop a custom-made device. During the manufacturing stage, the shape, support points, and protection limits were defined.

The mask's primary function is to protect the injured region from new impacts during recovery. The material, combined with the device's design and support points, helps absorb and distribute the force of any potential blow, reducing its concentration on the fractured area.

Danilo's mask is not a novelty in football. During the 2026 FIFA World Cup, England left-back Djed Spence used similar equipment after suffering a jaw fracture shortly before the tournament. Despite serving the same purpose, the protectors were made from different materials: the English player's was constructed from carbon fibre, while Danilo's uses TPU, which offers greater force-absorption potential.

"It is important to highlight that the facial protector does not completely eliminate the risk of further injury, but it is an important resource for increasing the athlete's protection during their gradual return to sporting activities," the coordinator explained.

Beyond durability, manufacturing must consider factors such as weight, comfort, stability, and field of vision. The mask cannot exert pressure on the injured region or shift during movement. Breathing, perspiration, and communication with teammates are also aspects considered in the design.

Adaptation to the equipment happens progressively. Initially, the athlete takes part in more controlled activities, and their response to training is observed before progressing to higher-intensity exercises. During this period, comfort, stability, field of vision, and any pressure points are evaluated, with adjustments made whenever necessary.

Since the mask's introduction, Flamengo's dental department has maintained constant contact with the physiotherapy and medical departments. Integrated care allows for monitoring of the player's progress and ensures the equipment remains suited to the needs of each recovery stage.

"The facial protector is a protective tool. The safety of the return also depends on the recovery from the injury, clinical progression, and the integrated work of Flamengo's entire healthcare department," Guto Ferreira stressed.

The professional also highlighted Danilo's dedication throughout the rehabilitation process. The defender's discipline and commitment have been fundamental to completing each recovery stage, respecting the time necessary for a safe return to the pitch.