3D printed orthopedic corset

Can an orthopedic corset be 3D printed?
And can it obtain the same properties as a manually crafted corset?

New digital manufacturing technology

Together with trusted professional partners, Create it REAL launches a new digital manufacturing technology to produce individual corsets, including 3D printing.

Besides moving away from traditional labor-intensive manufacturing, our 3D printing solution for customized corsets also introduces remarkable features for the user’s benefit and a circular economy scheme.

Our solution allows for designing customized corsets with gradient stiffness and more flexible zones. Ventilation zones with defined holes are also an option. The technology enables the professional to define different areas and 3D print in one workflow.

Hence, you avoid time-consuming efforts in manually modifying the corset with modifications and many materials combined and glued together. An optimized workflow will give the orthopedic workshop more time for the end user.

Orthopedic professionals spend a tremendous amount of time supporting and guiding patients that suffer from spinal and posture problems such as scoliosis. Once they find that a spinal brace or an orthopedic corset is the best-suited solution to relieve and support the patients, they start capturing measurements and designing the corset before manufacturing can commence.

Read on for details on how our automatic CAM corset solution works. And how value is added to the production workflow and for the end-users.

Typically, the production of a corset requires high knowledge and experience. Additionally, it takes a significant amount of time to craft a nicely fitting corset manually, and the process includes various technologies and machinery such as plastering, molding, and light milling.

Orthotics & Prosthetics print service

Get your seat, corset, socket, or cast 3D printed in top quality. We use your own custom design and meet your requirements for material, strength, quality, and functionality.

Great user benefits

The end-user of the 3D-printed corset will experience advanced support while remaining lightweight. Our 3D-printed corset fulfills the medical requirements and is made with polypropylene material.

The 3d printed corset has high comfort with different stiffness zones for extra support and flexible zones for flexibility to support the spine of the end-user in the best possible way.

  • Lightweight
  • Different modifiers for strength and flexibility
  • Can provide good ventilation with air holes

Furthermore, this solution supports the transition into a more sustainable way of manufacturing without generating a significant amount of waste.

Advanced solution

The production of a 3D-printed spinal corset is made in several steps:

  • First, we need a 3D model to make the design file. Typically, the patient must have a professional scan of the upper body made at an orthopedic clinic. A 3D scanner then collects all the data points and details from the patient into a 3D model.

 

  • Second, the scanned 3D model is loaded into a CAD design tool where the orthopedic specialist can modify it to fit the patients and provide support in the right places. The design model is enhanced by defining zones with different stiffness and when appropriate zones for ventilation.

 

  • Finally, the corset is printed on a specially designed 3D printer. The 3D printing technology is a simple-to-operate 3D FDM (fused deposition modeling) printer without requiring highly skilled crafting labor.

User-friendly CAM software

Start processing by importing the 3D models (from your CAD software) as an STL file of the corset in our professional REALvision CAM 3D software. You can modify the parameters for printing the corset and change the stiffness zones or infill types to optimize the final result before making the 3D print file.

  • Stiffness mapping: Select from 3 options: SOFT, MEDIUM, FIRM
  • Ventilation mapping: Select from 3 options: LIGHT, MEDIUM, HIGH Airflow
  • Trim line: Select the width and properties for the edge area 
  • Printing time and material consumption
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Printed in PolyPropylene material

We use 3D print filament made from PP (PolyPropylene) material. Today, most customized corsets are made with PP, an approved material for orthopedic corsets.

From a manufacturing point of view, using the printing process limits the waste to zero, and with a recycling scheme of the corset, the environmental footprint is reduced significantly.

Another advantage of using additive manufacturing technologies with melting plastic parts as infill is that it ensures a no-dust production environment. There is no hindrance to operating the 3D printing production in a standard office environment.

After printing, the corset might have straps added like in traditional crafting.

Unique 3D printer solution

Together with a partner, we provide the corset printing solution:

  • Embrace Corsetmaker
  • Corsetprinter optimized for high-end PP for a smooth result. 
  • Three-dimensional workspace:
    60cm x 60cm x 65cm
  • Material properties: Certified and approved PP filament
  • Automatic spool change system
  • Optional: white-labeled version of the 3D printing software

Short return of investment period

Our 3D printing solution is attainable even for smaller O&P workshops making the return on investment period very short.
All you need to get started is 3D modeling software or an STL file, 3D printing software, the FDM printer, and filament. Talk to us about how to start with actual production, where the process is replicable, traceable, and validated. This solution is not for prototyping but will take you to actual output once installed at your premises.

Ready to join the 3D printing revolution?

We challenge the status quo, wasteful production processes, and traditional markets to adopt new materials and technologies. Mass customization is one of the most significant advantages of this technology, as it enables straightforward print service and production within a few days of delivery. Many people still calculate 3D printing as a prototype technology for hobbyists. We invite you as a professional CPO, clinician, or orthopedic technician to join us in the 3D printing revolution by rapidly producing printed products, such as the wheelchair seat, cost-effectively and adding more value for the end user.