Additive In-Time Manufacturing of Customised Orthoses

Additive manufacturing of plastic components in medical technology enables greater freedom of design when designing patient-specific products, in particular, in production of customised medical products, such as orthoses. In the present contribution, the advantages of a digital process chain are combined, from the 3D scan of the patient to CAD-supported modelling of the corrective form and the orthosis design until the path planning of a printable geometry. The main disadvantages of current additive printing techniques, such as the fused filament fabrication (FFF) process, are high printing times (>12 h) for larger components as well as the low degree of freedom in the 2.5D printing technique that prevent the subsequent application of geometry features to the product. The fast SEAMHex (Screw Extrusion Additive Manufacturing) printing technology with a hexapod kinematic printing bed provides a solution to the mentioned difficulties. Consequently, the high-performance printer has been prepared for the individual requirements of medical technology in terms of materials and geometries. An effective additive manufacturing process has been realised and tested in combination with a digital process chain for orthosis modelling.