Crispin Orthotics needed a way to quickly and cost-effectively produce custom ankle-foot orthoses for individuals with neurological conditions such as cerebral vascular accident (CVA). Traditional methods were too slow and could not offer the necessary precision for individualized adjustments
Creating personalized 3D printed orthoses for improved comfort and aesthetics
Summary
Challenge
Solution
Crispin Orthotics utilized HP’s 3D printing technology with HP 3D HR PA 12 material to produce highly accurate, customizable ankle-foot orthoses. The ability to create both modular and custom designs allowed for precise adjustments based on the patient’s specific needs.
Value
The 3D printing solution provided a faster, more efficient way to produce personalized orthoses, reducing production time significantly. It also enhanced the aesthetic and functional qualities of the devices, making them more comfortable and tailored to the patient’s needs.
Products & Services
- HP MJF Technology
- HP 3D HR PA 12 Material
- Post-processing: Bead blasting, Dyed finishing, Dyed lacquer sealant
- In-house design and integration
AM Maturity Model
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5
Strategy
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AM is integrated as a core technology, driving innovation in custom orthotics. The approach aligns with both healthcare and product development strategies.
S5
Product Design
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AM allows for customization and personalization, using 3D scans to design tailored orthotics. The focus is on functional and cosmetic design with lightweight, cost-effective solutions.
Could further specify the role of DfAM in optimizing the design process.
PD5
Material
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HP 3D HR PA 12 material is used, chosen for its durability and flexibility in dynamic applications.
M5
Process Engineering
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The design process is highly iterative, with AM enabling rapid prototyping and testing for functionality and fit. The use of HP Multi Jet Fusion enables precise and efficient production.
PE4
PE5
Production Setup
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The use of AM reduces production complexity, allowing for cost-effective small-batch production.
PS5
Manufacturing Execution
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Manual process.
ME3
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ME5
Quality
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Product and Process quality planned and inspected for manufacturing process compliant with industry standards.
Q4
Q5
Maintenance & Service
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Regular printer maintenance.
MS5
Environmental Sustainability
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Using 3D printing technology reduces waste and avoids the use of environmentally harmful materials like carbon fiber.
ES5
People & Organization
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Competency development and employee training in AM are well established.
PO4
PO5
Evaluate your additive manufacturing capabilities across 10 different dimensions.
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