3D printed hybrid orthoses
made with passion

We redefine orthoses. Our aim is not only to change this piece of orthopedic
equipment into something that the patient will finally accept, but also like at last.

A few words about the project

Introducing automation in the industry where every product requires a bespoke approach is not an easy task. Orthotics falls into one of those fields, as each device for children with motor disabilities needs made-to-measure customisations.

Increasing precision and functionalities of orthoses produced using the traditional method are limited. The aim of Ortheo3D is to expand these possibilities by involving modern technologies, such as 3D scanning and additive manufacturing 3D printing in order to shorten the waiting time and increase comfort for the little patients. The need for orthoses is constantly growing not only in Poland, but worldwide.

Nowadays, orthoses’ users struggle with the following difficulties:

  • casting measurements are a time-consuming and unpleasant experience for children,
  • due to imprecise measurement tools orthoses are uncomfortable and do not fit properly,
  • long waiting time: 4-5 weeks,
  • orthoses are bulky and in effect patients need to buy oversized shoes to fit them.

Those factors have a direct impact on the effectiveness of children’ rehabilitation and treatment. Ortheo3D wants to introduce orthotics to modern technologies in order to eliminate casting measures and shorten production time as well as to improve the fit and therapeutic parameters of orthoses.

Furthermore, AI implementation is going to change the future of orthotics. Not only will it systematize current orthotic knowledge, but may also create a whole new perspective and approach to the orthotic treatment. Combining artificial intelligence with an online platform gives an opportunity for orthotists, physiotherapists and doctors to grow and consult cases of their patients together.

Building this innovative technology is based on the highest quality equipment and gait laboratory data combined with specialists expertise. Ortheo3D partners will receive the access to the platform with built in algorithms, so that despite limited diagnostic equipment, they will still be able to deliver the highest quality orthotic devices.

One must not forget that the experience of children and their parents should always stand as a priority. Optimisation of wall thickness and orthosis shape will enable patients to wear standard shoes, but concurrently applying a modern, stylish design will be possible. Ability of an independent put on and take off of orthosis or every additional step that a child can make are enormous changes affecting general development. Ortheo3D answers patient needs and aims to improve the quality of children’s everyday life.

What features make our orthoses so special?

  • Light – shape optimisation and decreased wall thickness of orthoses allowed for reducing the overall weight of orthotic devices,
  • Comfortable – innovative methods of measurements along with computer-aided design provide a better fit and increased functionalities tailored to the patient anatomy and needs,
  • Aesthetic – modern design, personalised patterns and breathable lattices: we are only limited by our imagination,
  • Produced in no time – shortened waiting time means patients receive their orthosis earlier and can wear it for longer, which effects the results of treatment,
  • Complex patient care – communication between doctors, physiotherapists and orthotists had never been easier: all it takes is to send a 3D visualisation of a designed orthosis and its alignment to consult the goals of therapy.

3D SCANNING - The foundation of a perfectly fitted orthosis is a correctly made measurement, which precisely reflects patient anatomy. 3D scanning provides the accuracy of 0.05 mm, which is unobtainable in traditional casting methods of measurement. The important aspect of this technology is shortening the measuring time to a couple of minutes, what not only affects the experience of a child, but also saves more valuable time for an orthotist, who can focus on gait analysis and orthosis assessment.

3D PRINTING - The innovative HP Multi Jet Fusion technology enables the production of durable, complex elements with an accuracy of 80 microns. The models are created in a powder-filled chamber, on which an appropriate agent is applied. Subsequent layers are joined by thermal energy generated by a UV lamp. Only the part of the powder that will form the element structure is consolidated, thanks to which the production is low-waste. The use of such innovative production methods allows for a fresh approach to orthotics by designing new solutions and improved shapes. Lattice structures, modular systems or personalised finishes? In 3D printing, it is not a challenge, it is everyday life.