Soft body jacket
The soft body jacket is a custom 3D-printed spinal orthosis made from soft TPU, offering a gentle alternative to rigid corsets.
More wearable
Easier breathing, better posture
Daily life becomes easier
Explore the advantages gained through a digital workflow:
- Custom fit, every time: Made from scan or measurement using digital tools, the brace is tailored to each patient’s needs and anatomy.
- Flexible design options: Optional zones of increased support, lightweight and easy-to-trim design, and mount velcro closures for adjustability.
Designs that deliver
Discover how professionals use our technology for young patients who need gentle yet effective postural support. It offers a comfortable alternative for children with neuromuscular scoliosis or other conditions where rigid plastic shells may be too harsh or not tolerated.
Soft body jacket for young patient
The first 3D-printed soft corset was made for a unique young patient in Cyprus who has NMS and spends many hours in a wheelchair daily. This results in a child’s inactive lifestyle and limits family flexibility. Neither the patient nor the family accepted the traditional correction brace. As professionals working with spinal treatment may recognize, the biggest issue with treatment plans is when the braces are not worn enough. Eleftherios and his team identified the need to design an alternative to help this young patient.
At their facility in Athens, Greece, Ortholife has the Embrace CorsetMaker solution, where he and the team enjoy the freedom to customize and create unique devices. This gave him the idea to make a soft brace in TPU. The 3D printers are specialized production systems, and printing the brace in a different material requires a completely new configuration. Therefore, he contacted the research and development department at Create it REAL to discuss his idea, and we started the project.
When to choose a soft body jacket
This device is ideal for:
- Children with neuromuscular scoliosis (NMS).
- Patients with cerebral palsy, muscular dystrophy, or spinal muscular atrophy.
- Postural support for wheelchair users.
- Early intervention in cases where hard braces are not yet accepted.
- Non-surgical candidates and patients sensitive to traditional braces.
Get better positioing support
Print on demand or power your own production line
Material advantages: Why flexible TPU adds value in spinal orthotics
The soft body jacket is manufactured in thermoplastic polyurethane (TPU), a digitally printable material with a unique combination of controlled flexibility, durability, and patient-specific adaptability, making it an ideal choice for complex pediatric cases.
Controlled flexibility for sensitive anatomies
TPU provides a semi-rigid structure that accommodates patient posture, tone, and asymmetry variations. Its inherent flexibility reduces pressure concentrations and allows better contouring around bony prominences, which is particularly beneficial for patients with neuromuscular conditions or scoliosis with pelvic obliquity.
Optimized for respiratory function
Unlike traditional rigid shells, TPU can be designed with variable stiffness zones to relieve compression across the thoracic region. This supports improved diaphragmatic expansion and facilitates better breathing, which is critical for patients with compromised respiratory function.
Durable and resilient
TPU is impact-resistant, resists deformation under cyclic loading, and maintains its shape over time, even under prolonged sitting conditions. This supports ease of use in pediatric seating systems and reduces handling strain for caregivers.
Full design control through digital manufacturing
3D printing with TPU enables precise control over wall thickness, flexibility gradients, and localized reinforcements—features that are difficult or impossible to achieve with thermoplastic vacuum forming. This improves fit, reduces adjustment time, and supports iterative refinements if needed.
A stepping stone to correction
For patients unable to tolerate rigid TLSOs, TPU-based soft body jackets offer a compliant, transitional solution, improving acceptance rates while delivering meaningful postural correction and support.
Frequently asked questions – Soft body jacket
What is the soft body jacket?
The soft body jacket is a custom-made spinal orthosis 3D printed from flexible TPU. It offers a softer, more adaptable alternative to traditional rigid corsets, especially for children with neuromuscular scoliosis and other complex conditions.
Who is the soft body jacket designed for?
It is ideal for:
- Children with neuromuscular scoliosis (NMS)
- Patients with cerebral palsy, muscular dystrophy, or spinal muscular atrophy
- Wheelchair users needing postural support
- Non-surgical candidates
- Patients who do not tolerate rigid TLSOs or require early-stage intervention
What makes the material different from traditional braces?
The brace is made from thermoplastic polyurethane (TPU), which provides controlled flexibility and durability. Unlike rigid polypropylene (PP), TPU adapts to a child’s anatomy, reduces pressure points, supports better breathing, and increases comfort during prolonged sitting.
How does the soft body jacket improve breathing and posture?
TPU’s flexibility allows relief zones over the thoracic region, enabling better diaphragmatic expansion. This helps improve head alignment, respiration, and trunk stability, which are essential for children with limited muscle tone or postural control.
Is the soft body jacket a permanent replacement for rigid braces?
Not necessarily. It can be used as a transitional device to improve compliance in treatment for patients requiring more rigid support. It may be a long-term solution for some children, especially non-surgical candidates.
How is the brace customized for each patient?
Each device is made from a scan, cast, or measure. Using advanced digital tools, orthotists can tailor the design to the patient’s anatomy and postural goals, including adding localized reinforcement or zones of increased stiffness.
What closure and design options are available?
The brace can be designed with anterior, posterior, or bi-valve openings. Velcro strap systems are standard, and the structure is lightweight and easy to trim or adjust.
Is the soft body jacket a certified medical device?
The soft body jacket is currently available through our 3D print service. It is also available as a manufacturing solution in the Embrace Corset solution.
How do I get started or request a device?
To explore whether the soft body jacket suits your patient or clinical setting, please contact us to discuss your case or request a prototype through our 3D print service.