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Home » 3D Learning Hub » 3D Printing Applications » How 3D printed orthotics can reshape a patient’s life
Orthotics are often life-changing devices that can reshape a patient’s life. To maximize their support, every orthotic has to be custom-made, as no two patients are the same, and size differs from person to person. In the past, custom-made devices were challenging to produce and had a considerable price tag. With the continuous development of 3D printing, it is set to revolutionize the healthcare industry and provide a great addition for fastly produced custom-made orthotics at an affordable price.
As an online 3D printing service Sculpteo has already worked with different clients to create orthotic devices. But how exactly can 3D printing be the missing puzzle piece? Let’s find out!
In general, orthotics are fitted externally and help to recover or support certain parts of the human body. There are devices for different body parts: the torso, head, upper extremities, like hands or arms, and lower extremities, such as legs and feet. The orthotics are also distinguished through their function: paralysis, relief, and soft.
Paralysis orthoses come into use when the patient has a total failure of their muscles or shows incomplete paralysis. The goal of paralysis orthoses is to help and support the patient in tackling functional limitations. Relief orthoses are often used after operations or after injuries. Soft braces are devices like a bandage that have the intent of protecting joints from too much load.
3D printing is a relatively new manufacturing technology that offers new ways to make proofs of concept, prototypes, or end products. 3D printing is an umbrella term for different printing techniques, such as plastic filaments, resins, powder, or metal. Often there is the assumption that those printed parts are rigid and bulky. However, through many different material innovations over the last few decades, many different materials have various properties, like flexibility and hardness.
Now that it is clear what orthotics and 3D printing are in general. What are the advantages of using 3D printing as a manufacturing process for orthotics?
The possibility of creating perfectly shaped orthotics is a big advantage of 3D printing. Traditional manufacturing processes could make pretty well-shaped orthotics. However, for the optimal care, support, and comfort of the patient 3D printing offers a whole new set of opportunities. With the help of a 3D scanner, an essential element for the whole process, the patient or a medical professional can create a 3D file. The 3D scanner opens the door for health professionals and manufacturers who do not have the perfect knowledge and skill to develop and design a device.
With its unique processing style, making 3D-printed orthotics is often cheaper than traditional orthotics. There is no big material waste, as the printer only uses as much material as it needs for the orthotics. Furthermore, producing just one device is easier without many additional costs.
3D printing also impresses with fast production, which is especially important when the orthotics are needed as fast as possible. It also allows for fast modifications if they are needed.
Working with additive manufacturing can often be quite intimidating, especially if it is an entirely new field. However, there is no reason to be anxious. Many 3D printing service providers have expertise not only in 3D printing but also in the medical sector. So collaborating with a service bureau is always a good idea to share knowledge and create the best possible result of a printed orthosis for the patient.
3D printing offers many innovative materials. However, not all are suited to skin contact. So which materials can be considered?
Nylon PA12 is a polymer powder that is perfectly suited to substitute injection molding plastics. Nylon PA12 is excellent for both experienced professionals and beginning designers because of its high precision and low cost.
PA11 is not only an excellent substitute for PA12 but is also suitable for skin contact and, therefore, a perfect material to print an orthotic with. Ultrasint® PA11 is a bio-derived powder with exceptionally high toughness. This material has the particularity of offering high ductility and impact strength for all applications.
Ultrasint® TPU01 has high flexibility and shock absorption properties and is perfect for footwear or orthopedic models.
It is possible to print orthotics on a desktop printer at home and use it. However, it is not always the best idea. Not all 3D printing materials are approved for skin contact, which is required when printing orthotics. Another option would be to let a 3D service bureau manufacture the brace. You would have many advantages when working with an online 3D-Printing service like Sculpteo.
No matter in which part of the process you need help. We are here. From the first idea to the first draft, design, and changes. Our experts at Sculpteo Studio always have an open ear and try to solve problems.
As a service bureau, we have many different industrial 3D printers. This saves you investment costs and the needed knowledge to operate those heavy machines.
When working and ordering with a 3D-printing service bureau, you have the luxury to lean back and let us do the work. After you upload your finished 3D file, we print the part and send it to your delivery address.
If you have any questions about the process or printing orthotics, please feel free to contact our team. They will be happy to help you find the correct answer.
You can find a lot more information on our website or through our Learning Hub, where we talk about all things 3D printing-related. You can also contact us directly.
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