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SLS 3D printing for Orthotics
An introduction to SLS 3D Printing for Orthotics
Many companies have recently switched from traditional manufacturing methods to 3D printing orthoses. Why is this happening now? And what is SLS 3D printing anyway?
PDF: An introduction to SLS 3D Printing for Orthotics
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Selecting an SLS 3D Printer for Orthoses
Today, almost any orthosis should be printable using the SLS 3D printing technology. Very large ones may require very expensive machines, though. Below are a few examples of what is already being done. The list is by no means complete, and companies regularly add new, innovative 3D-printed orthoses to their product range.
Which SLS 3D printer is most suitable for printing orthoses? This depends on several aspects. In most cases, the very large, industrial SLS 3D printers are too expensive and too demanding in terms of operator skills, industrial facilities with separate ventilation and special power outlets. Instead, look for the machines that you can rent.
A foot and ankle orthosis heals foot drop caused by ankle dorsiflexion during the swing phase. This is one of the most used rehabilitation devices. When built through 3D printing technology, it gives better accuracy and faster results.
Choosing an SLS 3D printer that can be placed in the offices of the people measuring the limbs of people, and training them on how to scan and print orthoses themselves, can cut both labour costs and production times dramatically.
Insoles are used in patients suffering from foot conditions. They help improve unstable walking and are suitable for patients suffering from cerebral palsy, diabetes, flat foot, varus and valgus foot, and other dysfunctions.
There are SLS 3D printers that offer a print volume large enough for adult insoles at a price that allows for competitive orthosis production, at least in countries where labour is both costly and sometimes hard to find.
The traditional methods of producing orthoses use plaster and graphite. The weight of orthosis is heavy and feels uncomfortable when worn for a prolonged period. This discourages the patients from wearing the device for long hours. In contrast, scoliosis orthosis produced by SLS 3D printing is way lighter and feels more comfortable. This orthosis is specifically used in patients developing scoliosis as it helps in fixing misalignments in the spine.
The headrest is specially designed to improve cervical spine curvature. It works by slightly alleviating the cervical spine. This is great for people suffering from cervical kyphosis (straightening of the cervical spine).
These orthoses encompass the forearm and the palm. They provide support to weak muscles and immobilize the movement at the wrist joint, thereby allowing only the fingers to move. They are suitable for rheumatoid arthritis, carpal tunnel syndrome, injury at the wrist joint, radial nerve palsy, and osteoarthritis.
Cranial orthoses are lightweight and feel comfortable. They are designed for children suffering from head-shape deformity, also known as flat head syndrome. A cranial orthosis is double-layered and lightweight which helps reshape the baby’s head.
Case: 3D printed orthosis replaces traditional plaster
The hand was scanned in with a 3D scanner and based on it, a model adapted for additive manufacturing in Wematter’s machines was developed. A number of variants were then set to be selected by the patient. The whole thing was supervised by the doctor who also decided to shift from traditional plaster to 3D printed orthoses.
The result is that the patient can now live a more accessible life with the opportunity to exercise, shower, wash dishes, and get dressed without problems. This is the first step to digitizing care and transferring experience and knowledge from industry to improve the everyday life of patients.
A complete ecosystem for orthotics production
SLS 3D printer
The Gravity SLS 3D printer and its ecosystem can be placed almost in any environment and is easy to get started with regardless of previous additive manufacturing experience.
Cloud software
Our Deep Space software lets you easily place 3D files in the virtual build volume and stack many copies on top of each other while keeping material consumption down.
Materials
We offer one of the broadest ranges of SLS powder for additive manufacturing, covering everything from really soft materials to ones made really stiff with fiber reinforcement.