3D printed hand brace from HP Multi Jet Fusion technology helps improve patient experiences

OT4 improves patient outcomes by creating custom orthotics with HP MJF.

Industry

Material

Challenge

To cut costs and improve outcomes for patients who wear orthotics and prosthetics.

Technology

Results

With HP Multi Jet Fusion technology and flexible materials, OT4 can create orthotics and prosthetics that move with patients.

CHALLENGE

Choosing the best 3D printer for custom orthotics

OT4 Orthopädietechnik GmbH has used various 3D printing technologies (e.g., SLS) to design, develop, and produce customized 3D printed orthotics and prosthetics, but these technologies involved expensive processes and materials, the latter of which led to powdery parts that were prone to breakage. Additionally, the cosmetics and aesthetics of these 3D printed products were not suitable or ideal for end users.

OT4 searched for a new way to produce a 3D printed hand brace, a device that can help support joints in the hand and keep the finger joint properly aligned.

“3D constructing using HP Multi Jet Fusion makes it possible to produce completely new products with a functionality that wasn’t possible up until now.”

Andreas Flamm, CEO, OT4 Orthopädietechnik GmbH

SOLUTION

The search for a 3D printer to make custom orthotics

OT4 was intrigued by HP Multi Jet Fusion (MJF) technology’s capability to produce high-quality parts made with the robust-yet-flexible HP 3D High Reusability (HR) PA 11 material.

"HP 3D HR PA 11 is a fantastic material for us because it is more dynamic," said Ian Spring, Head of Design and Development at OT4. "We are creating products that go on people's bodies. They are moving all the time, and the material has to move too."

3D printed orthotics "must continuously withstand strong elongating forces and must be flexible", according to Andreas Flamm, CEO of OT4. "Thin-wall printing using HP 3D HR PA 11 has produced good results. We can make products thinner, lighter, easier to clean, and softer on the skin."

RESULTS

Cost and time savings for 3D printed hand braces

With HP MJF technology, OT4 is now able to produce 3D printed orthotics, like a 3D printed hand brace, without the need to apply expensive post-processing. 3D printed orthotic parts produced with HP MJF have the same properties in x, y, and z directions, which means the build chamber space can be maximized for each production job and with optimal nesting. This, in turn, can help drive down costs.

"Using HP Multi Jet Fusion can save us 30% in costs compared to other 3D printing technologies," Spring said.

Aesthetically, creating orthotics and prosthetics using HP MJF resulted in stronger, more robust surfaces and more technically appealing devices. The process also saves times for the orthotist.

"Thanks to HP Multi Jet Fusion, we at OT4 can save an orthotist up to 10 hours of work compared to using common techniques, depending on the part," Flamm says.

Orthotists also can develop a 3D printed hand brace that fits each patient’s unique anatomy, achieving both flexibility and durability.

Spring adds: "We can bring in new features and new functions, and increase the quality of life for our patients even more."

Interested in learning more about HP 3D Printing Solutions?

Disclaimers

All images data courtesy of OT4 Orthopädietechnik GmbH
HP Jet Fusion 3D Printing Solutions using HP 3D High Reusability PA 11 provide up to 70% powder reusability ratio, producing functional parts batch after batch. For testing, material is aged in real printing conditions and powder is tracked by generations (worst case for reusability). Parts are then made from each generation and tested for mechanical properties and accuracy.

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