The Technology Behind 3D Printed Prosthetics From Design to Fabrication

The role of 3D printing in orthopedics has had a significant impact throughout the last few years with innovative tools that help CPOs give the most efficient devices to their patients.

This approach to medical care gives the promise of faster, more personalized and cost-effective prosthetic devices.

The aim of this article is to understand how 3D printing in prosthetic devices works and what are its benefits and limitations.

Understanding 3D printing in prosthetics

3D printing in prosthetics refers to the use of 3D printing technology to customize and print prosthetics like hands, foot, etc. The use of CAD/CAM solutions gives multiple advantages to CPOs and their patients:

– Customization: CAD software gives CPOs the power to produce prosthetics that fit perfectly well the patient’s body measurements and medical needs.

– Lightweight: Thanks to new materials, CPOs can create lighter devices that are more comfortable for patients.

– Affordability: With streamlined production and lower material costs, the devices are accessible and more affordable.

The common materials used in CAD/CAM are:

TPU (Thermoplastic Polyurethane): it is a flexible and thermoformable material.

PP (Polypropylene): lightweight and resistant, used for rigid components like limb devices.

The digital workflow: from scan to 3D pint

3D printing gives a more streamlined and easy approach to manufacturing. The digitalization of tools used gives a faster application of orthopedics steps:

Step 1: 3D scanning

The CPO takes a scan of the patient anatomy that is super precise. 3D scans like Captevia Plus or 3DSizeMe give CPOs the right tool to get the best scan of the patient’s member.

The advantage of this step is that it is non-invasive for the patient and really fast. The 3D scan can then be downloaded and even saved to be reused in the future.

Step 2: Computer-aided design (CAD) / rectification software

After taking a scan of the patient anatomy, the CPO can start doing rectification and customization thanks to advanced software like Cube or Fitflow. This is an essential part of CAD/CAM that gives the patient the most fitting device.

The advantages of CAD are that it is easy for the CPO to visualize and correct the device and replicate or save the model for future use.

Step 3: 3D printing

The final step is to produce the digital model created during the second step. The CPO sends the corrected model created with the software to be 3D printed.

This step is automated and gives quick production time to both the CPO and the patient. Moreover, 3D printing gives a good environmental advantage with reduction waste.

: Materials for 3D-printed prosthetics

CPOs can use various materials to 3D print orthopedical devices. Depending on the aim of the device, some materials are more interesting than others and are key to a strong, comfortable and suitable device.

The two main materials used here at Qwadra are:

TPU (Thermoplastic Polyurethane) : Perfectly used with Arkad and Sona Flex, it allows practitioners to create effective devices without losing the plastic property.

PP (Polypropylene): Strong and hard enough to be used for limb devices.

Material choice has an impact on strength, flexibility, weight and patient comfort.

– Strength and durability: it is important to make sure the patient has high-quality equipment

– Flexibility and movement: This is a crucial point as it is important for comfort and mobility

– Weight: thanks to a lighter structure, it reduces fatigue for the patient

– Patient comfort: breathable structure improves daily use of the device

– Sustainability: with 3D printing, practitioners are considerably reducing their waste.

Benefits and limitations of 3D-printed prosthetics

There are many benefits with 3D-printed prosthetics, which are convenient for both the practitioner and the patient.

3D-printed prosthetics allow practitioners to create personalized designs at a lower cost, making them more accessible.

The precise tailoring enabled by 3D printing ensures a comfortable and functional prosthetic that is suited for the patient’s specific needs.

The speed of the 3D printing process allows for quick design and faster delivery of the patient’s device, which is beneficial for those in need of fast solutions.

Even though 3D printing has its advantages, it also has limitations which should be considered:

There are limits on the materials available, some of them are not suitable for a use that involves a lot of force or for long periods of time.

Some devices may require surface finish to make the textures smoother which require a complementary time to do so.

Then, the practitioners must be trained in the different steps of this workflow: from scanning, to modelling and printing.

3D printing is a new chapter in prosthetic fabrication. Thanks to it, practitioners can fastly deliver personalized and affordable devices. This innovation empowers CPOs to give the best solutions to their patients.

With a continuing evolution of materials and technics, 3D printed prosthetics are becoming a more reliable, comfortable and sustainable solution.