Researchers in Berlin are using digital technologies, including 3D printing and additive manufacturing, to create ready-to-use, custom-fit orthopaedic prostheses in just eight hours.
German researchers revolutionise orthopaedic manufacturing
- 22 November 2019
We are working to make the orthopaedic manufacturing processes more intelligent by using digital technology.
Although sophisticated and high-tech, today’s orthopaedic prostheses are still primarily manufactured by hand. Typically, technicians start by scanning a patient’s bone structures and then taking their measurements. Using this information, a plaster cast is created. With this cast, the technician works with the patient to make sure the size and fit are correct. Once the right fit is achieved, the technician uses the cast to create the final prosthesis via a process that involves manual lamination of carbon fabric materials.
The problem with this process is that it is slow, tedious – and costly. That is why the EU-funded ADDcarbori project is bringing orthopaedic prosthesis manufacturing into the digital age. Using a combination of digital scanning technology and modern 3D printing, the project is making the manufacturing process more efficient and the product more effective.
Speedy manufacturing
Researchers developed an innovative ‘data glove’ that can be used to measure a patient’s entire body (as opposed to just a single section) via a single scanning procedure. This data is used to provide the 3D printer with the information it needs to automatically produce the required prosthesis.
The custom-made prosthesis is created on-the-spot, printed using special carbon fibres that offer high durability. To apply these carbon fibres onto the orthopaedic prosthesis’ complex surface, the project developed an innovative additive manufacturing process that uses an industrial robot with multiple 3D printing heads.
According to project researchers, this entire process – from scan to prosthesis – takes a maximum of eight hours.
A successful collaboration
The ADDcarbori project is a joint initiative between Makea Industries, Rehabtech Research Lab, and the Technical University of Berlin. Together, these partners successfully demonstrated the capability of printing endless carbon fibres onto previously printed 3D shapes, resulting in a fibre-reinforced part that is both stronger and lighter than parts made using conventional 3D printing processes.
As a result of this project, Makea Industries gained the know-how and experience it needs to enter the lucrative additive manufacturing market.
Total investment and EU funding
Total investment for the project “ADDcarbori - additive production method of carbon fibre reinforced supporting systems for individual patient care” is EUR 412 436, with the EU’s European Regional Development Fund contributing EUR 206 218 through the “Berlin” Operational Programme for the 2014-2020 programming period. The investment falls under the priority “Research and innovation”.