3D-printed orthoses in PA11 and TPU were rough and porous,absorbing sweat and irritating skin. Needed a way to achieve smooth, sterile, long-wear surfaces for patient comfort.
Adoption of AMT PostPro Vapor Smoothing for their orthoses,transforming porous HP MJF parts into sealed, smooth, sterilizable surfaces. Integrated via Orthobroker’s OrthoSolid platform to deliver customized, hygienic, durable orthoses at scale.
Strategy Additive manufacturing is established as regular production process. AM activities are integrated across departments.Benefits from Additive Manufacturing as speed, freedom of design, resilience are systematically leveraged to create competitive advantage and strategic success.
Product Design Company-wide integration of AM into PLM with advanced tool landscape. Holistic sustainability approach shaping best practices for industry compliance.
Material The long term availability of materials are secured by 2nd sourcing and global supply. Selection of materials are application-centric and considering specifics for markets & business case.
Process Engineering In-depth understanding of holistic process chain and influences on the process and part quality to reach reproducibility across different lines and locations. Usage of simulations and models to support production engineering with a digital process twin.
Production Setup Integrated automation scenario with isolated automation islands covering the majority of process steps. Semi-automated handling throughout process chain. Operator is guided digitally in his work. Holistic production system for AM defined.
Manufacturing Execution Mainly automated process and asset creation with flexible allocation and execution based on real time data from shop floor, in a comprehensive and interoperable system. Tracking and integration of 2nd level production streams (i.e. powder management, build plate refurbishment).
Quality Preventive actions based on tracked quality, process, and material data are applied autonomously with counter- measures to ensure needed quality and reproducibility. Reproducibility under dynamically changing conditions can be continuously ensured.
Maintenance & Service Maintenance includes calibration and quality testing, with a fixed service framework to ensure high uptime. Data is leveraged to reduce downtime, and trained staff perform extended internal maintenance.
Environmental Sustainability Fully integrated sustainability practices; continuous monitoring and improvement; real-time energy tracking and adaptive material use strategies.
People & Organization AM process chain is integrated part of organizations‘ training programs, all relevant employees are trained right-time in a structured way. It lives a culture of self-driven learning and embrazes to challenge existing processes and organizational setup.
