3D printer for personalised orthotic devices

[Ryan_m_b]

Orthotics are externally applied devices that modify the structure and function of muscular and skeletal systems. They help patients with a variety of conditions from fracture recovery to degenerative diseases like spina bifida. Personalised devices can take months to hand craft and be quite expensive for the health service but research like this promises to not only speed up but lower the cost. I'm not much of a medical device guy but stuff like this really excites me. Such a simple solution that could help so many patients without costing an arm and a leg.

Embracing additive manufacture: implications for foot and ankle orthosis design.
Telfer S, Pallari J, Munguia J, Dalgarno K, McGeough M, Woodburn J.
BMC Musculoskeletal Disorders. 2012;13:84
http://www.biomedcentral.com/1471-2474/13/84/abstract

3D printer 'could help millions walk', say researchers
http://www.bbc.co.uk/news/uk-scotland-20031657

 

[berkeman]

Interesting. I've been told by our MEs that the 3-D printers we use here at my work have a limitation in the materials that can be used -- one of the limitations is that the final plastic pieces are not very strong, and are a bit brittle. I wonder if there are other materials that are compatible with the 3-D printing processes that have higher strength and toughness. It would seem that orthotics would need to be fairly strong, depending on the application...

 

[Pythagorean]

I have a friend who builds repraps (a low budget 3D printer) with his reprap. The pieces that come out are pretty strong; you can select a variety of plastics for extrusion.

 

[AlephZero]

The range of materials that can be used and the techniques to "cure" them, are still developing, but AFAIK the materials are limited to plastics and polymers.

There are research projects effectively doing "3D printing" of metal objects, using a computer controlled electric welder to build a solid object entirely from welding wire (Google for "shaped metal deposition") but that is probably outside of your price range.

You could consider using a 3D-printed object to create a mould for casting a metal part, using the "lost wax" casting process. The basic idea is
1. Make the 3D shape from a low melting point material
2. Spray coat it with a material (e.g. a ceramic) that can withstand the metal casting operation.
3. Remove the original material by melting it out of the ceramic mould.
4. Cast the object in metal.

This can produce very high quality components (both surface finish and material properties) from any castable material. You might be able to find a specialist foundry that can work from your 3D printed parts.

 

[LudusRex]

I find the potential applications of 3D printing technology in the field of personalized orthotic devices to be extremely promising. This innovative approach has the potential to greatly improve the treatment and management of various musculoskeletal conditions, while also reducing costs and wait times for patients.

Traditional methods of creating orthotics can be time-consuming and expensive, often requiring months of handcrafting and specialized skills. The use of 3D printing technology allows for a more efficient and cost-effective process, with the ability to create personalized devices in a shorter amount of time. This has the potential to greatly benefit patients who require orthotics for conditions such as fractures or degenerative diseases like spina bifida.

The research highlighted in the BMC Musculoskeletal Disorders article and the BBC News article is a great example of how embracing additive manufacturing can lead to significant advancements in healthcare. By utilizing 3D printing technology, researchers and clinicians can work together to design and create orthotic devices that are tailored to the individual needs of each patient. This can ultimately lead to better treatment outcomes and improved quality of life for patients.

I am excited to see how this technology continues to develop and be implemented in the healthcare industry. I believe that embracing innovative solutions such as 3D printing can greatly benefit society and improve the lives of individuals who require orthotic devices.