Custom made 3D printed devices for the perfect fit.
Imagine a world where orthotic and prosthetic devices are custom made to fit perfectly, providing unparalled comfort and support. With cost-effective materials and faster fabrication time, 3D printing is revolutionizing the field. “Personalized medical devices are growing in popularity among healthcare providers because they have been clinically proven to improve patient outcomes and reduce the cost of care.” (nTop 2023) 3D printing allows for in-depth customization of devices, leading to better patient satisfaction and higher compliance with the orthotic and prosthetic devices. Faster fabrication time and more comfortable materials are additional benefits over traditional methods of creating lower extremity orthotic and prosthetic braces.
Understanding Lower Extremity Orthotic Bracing
Lower extremity orthotic bracing can be used for a wide range of diagnoses and conditions, such as foot pain, leg or foot deformities, fracture management, postsurgical stabilization, spinal cord injury, contracture management (decreased joint range of motion), multiple sclerosis, Charcot-Marie-Tooth disease, Polio, arthritis, diabetes, neuromuscular weakness, nerve injuries, peripheral vascular disease, burn management, Cerebral Palsy, and Muscular Dystrophy (Rehabilitation Medicine, 2023). These devices improve biomechanical function, maintain or improve proper/neutral joint alignment, or protect a limb. Orthoses for the lower limb include knee braces, ankle-foot orthoses (AFOs), ankle braces, knee-ankle-foot orthoses (KAFOs), foot orthoses (FOs), and other off-the-shelf options.
The Traditional Approach
The traditional approach to orthotic bracing, particularly lower extremity bracing, involves hand casting with materials like plaster of Paris or fiberglass. Practitioners create a negative model of the extremity, fill it with liquid plaster, then excavate and modify the mold. This process can take a week or more, depending on the availability of staff and materials. It also creates significant waste, which 3D printing substantially reduces. Traditional methods allow for customization but leave room for error in casting, measurements, modifications, and fabrication—areas where 3D printing and additive manufacturing excel.
3D Printing of Orthotic and Prosthetic Devices
Creating a 3D printed orthotic or prosthetic device starts with either a scan or measurements. Digital scans, often taken on a tablet or phone, capture a 3D rendition of the limb. These types of scans ensure correct anatomical positioning for the desired device correction. Alternatively, measurements can be used to create a 3D model in computer software based on a more traditional casting method or using the Symphonie Aqua System. The scan is then sent to a computer with CAD (computer-aided design) software for modification, where customization and fit begin. The precise accuracy of scanners and CAD systems allow for orthoses and prostheses to fit patients perfectly with minimal adjustments during fitting. The scans are then sent to a printer, which uses material to create the device. Additional machines dye and smooth the braces, with some assembly required for pieces like ankle foot orthotics (AFOs), ankle gauntlets, and foot orthotics. Automation and swift modifications significantly reduce fabrication time, delivering custom-fit devices to patients quicker.
Future Prospects of 3D Printing
Research into 3D printing continues to explore new materials, durability, strength, costs, ease of use, and patient feedback. This newer process still has some aspects to work out and fine tune, but there have been many positives for both practitioners and patients. Innovations like different flexibilities in parts of an AFO, ventilation areas on an ankle gauntlet, and preplaced spaces for joints or rivets speed up fabrication and improve comfort and usability for patients. 3D printing is changing the orthotics industry by increasing efficiency, reducing waste, and improving the fit, comfort, and function of devices. 3D printing is not just used for lower extremity devices, but is also being utilized in upper, spinal and cranial orthoses, as well as prosthetically with sockets. At Tillges, we are the leaders in orthotic and prosthetic 3D printing as we currently are 3D printing several specialty braces and prosthetic sockets, please reach out with any questions or for more information on anything you see on our website!
RESOURCES
- nTop. (2023, January 24). 3D printing orthotics: A complete guide. https://www.ntop.com/resources/blog/3d-printing-orthotics-a-complete-guide/
- Rehabilitation Medicine. (2023). Orthoses (braces). Orthoses (Braces) | University of Michigan Health. https://www.uofmhealth.org/conditions-treatments/rehabilitation/orthoses