Customized orthosis in 48 hours thanks to 3D printing

We have been helping companies and institutions to implement additive manufacturing processes for years – always with the aim of optimizing processes. We serve customers from all sectors, from engineering and mechanical engineering to hospitals and dental laboratories. The solutions must always be suitable and deliver progress in terms of cost, time, effort and accuracy.
But this time I needed the full potential of additive manufacturing myself. I broke my forearm (radius) during the first heatwave of the summer, of all times. After just two days, it was clear that I would struggle for the next six weeks with the standard splint I received from the doctor. It is simply too big and rigid, which restricts me unnecessarily. It is also tightly sealed with foam and bandages – an additional burden in these temperatures.
I needed a customized orthosis. I informed my doctor that I would like to make it myself using 3D printing – he gave me the go-ahead.

3D scan of the body part with the peel3

Back at the company, I took off the splint and scanned my forearm with the help of my colleague Nicolas and the Peel 3 3D scanner. peel3D offers a special function in its standard software for scanning people or body parts. This makes it easy, as the scan only takes a few minutes. The scan is also so precise that we didn’t have to invest any time in post-processing, but could simply export the 3D file (.stl).

From 3D scan to orthosis model

As I am not an orthopaedic surgeon, I had to do a little research to find suitable software that would enable me to model an orthosis quickly and easily. With “Mecuris” I found an easy-to-use browser-based software. I used it to model the orthosis, including the holes for the fastener, in around 20 minutes.
The software actually also offers the option of setting patterns and motifs. However, as I was looking for a model that was as airy as possible for the current season, I didn’t use this option. I exported the orthosis again and imported it into the CAD software Autodesk Fusion 360. I also generated a Vonoroi with STG Vonoroi SVG Generator. I then transferred this to my orthosis on the basis of a process. Now all I had to do was export my finished orthosis model again.
Depending on the case, the creation of the orthosis model will take around 20-60 minutes, depending on practice and expertise. As a layman, I have to say that I was pleasantly surprised at how simple and intuitive orthotic software is today.

From orthosis model to orthosis

The rest was again child’s play for me. I loaded the finished model into the PreForm software from Formlabs and selected the SLS 3D printer Fuse 1+ with Nylon 11. The nylon 11 from Formlabs is perfect for this application, because on the one hand it offers sufficient strength and yet enough flexibility. On the other hand, the material is biocompatible, i.e. skin-friendly, which makes it completely unproblematic to wear. As the installation space of the Fuse 1+ offers sufficient room, I duplicated the orthosis so that I have one to change. We filled the rest of the space with other parts. Then all I had to do was load the print job onto the machine. Preparing and starting the print takes a maximum of 20 minutes.
After around 22 hours of printing and 10 hours of cooling, the splints were ready to be removed. The build chamber is removed from the Fuse 1+ and pushed into the Fuse Sift post-processing station. There, the unsintered powder is removed with a brush. This takes about 15 minutes. The orthoses were then briefly sandblasted and were ready for use.

Conclusion

It took me a total of around 35 hours to complete my customized splints. Of course, I also had them approved by my doctor. Instead of being 100% unable to work, I am now 50% able to work again and my well-being has improved massively.
My personal experience shows the great potential that the production of 3D-printed orthoses holds for doctors and orthopaedic technicians and that 3D printing can significantly improve the well-being of patients.
Please contact us if you have any further questions on this topic or if you are interested in testing the digital workflow yourself.