3D scanning and 3D printing technologies support orthopaedic brace customisation

3D scanning and 3D printing technologies support orthopaedic brace customisation


The field of orthopaedics has been continuously evolving over the years, driven by advancements in medical technology and innovative approaches to patient care. Among these breakthroughs, 3D scanning and 3D printing technologies have emerged as powerful tools that support orthopaedic brace customisation. Traditional orthopaedic braces have served their purpose for decades, but the integration of 3D technologies has revolutionized the way braces are designed and manufactured. This blog post delves into the transformative impact of 3D scanning and 3D printing in orthopaedic brace customisation, showcasing how these cutting-edge techniques enhance patient outcomes, improve treatment efficiency, and empower clinicians with unprecedented precision and versatility.

The Limitations of Traditional Orthopaedic Braces

Conventional orthopaedic braces, while effective in providing support and stabilization, often present certain limitations. These braces are typically produced through a laborious and time-consuming manual process, involving casting and molding to fit a patient’s specific anatomy. As a result, the fit of the brace may not be perfectly tailored to the individual, leading to discomfort, reduced efficacy, and potential skin-related issues. Moreover, the one-size-fits-all approach restricts customization, limiting the brace’s ability to address unique patient needs and complex musculoskeletal conditions.

The Power of 3D Scanning in Orthopaedic Brace Customisation

Integrating 3D scanning technology into the orthopaedic brace customisation process has been a game-changer. This non-invasive and quick procedure allows clinicians to capture a high-resolution digital model of the patient’s affected limb, creating a detailed representation of the anatomy in a matter of minutes. The 3D scan accurately captures the contours, dimensions, and specific characteristics of the limb, forming the foundation for a precisely customised brace.

Through 3D scanning, clinicians gain a comprehensive understanding of the patient’s unique anatomy, enabling them to design a brace that provides optimal support, alignment, and comfort. The ability to visualize and manipulate the digital model offers unparalleled insights, reducing the risk of human error and minimizing the need for multiple fittings. This not only expedites the brace manufacturing process but also ensures a perfect fit, enhancing patient compliance and treatment effectiveness.

The Revolutionary Role of 3D Printing in Orthopaedic Brace Production

With the 3D scan as the foundation, 3D printing technology takes center stage in the fabrication of orthopaedic braces. Additive manufacturing allows for the creation of highly personalized and intricate structures, enabling the incorporation of unique features and functionalities tailored to the patient’s needs. 3D printing materials range from lightweight and flexible polymers to durable and bioresorbable composites, offering an array of options for different orthopaedic applications.

The design freedom provided by 3D printing empowers orthopaedic specialists to create braces with varying thicknesses, ventilation channels, and targeted reinforcement, optimizing both support and breathability. Additionally, the ability to 3D print patient-specific patterns and textures on the brace’s inner surface enhances comfort and reduces the risk of skin irritation or pressure sores, a common concern with conventional braces.

Improving Patient Outcomes through 3D Scanning and 3D Printing

The amalgamation of 3D scanning and 3D printing technologies results in orthopaedic braces that are truly customized to fit each patient’s unique anatomy and clinical requirements. By minimizing discrepancies between the brace and the limb, the risk of pressure points and discomfort is significantly reduced, leading to increased patient compliance and improved treatment outcomes.

Furthermore, 3D-printed orthopaedic braces often exhibit superior biomechanical performance compared to their traditionally manufactured counterparts. The ability to fine-tune material properties and geometries ensures that the brace provides the necessary support and stability while allowing for optimal movement and range of motion. For patients recovering from fractures, ligament injuries, or musculoskeletal deformities, this level of personalized orthopaedic care can accelerate healing and rehabilitation.

Enhancing Clinician Productivity and Workflow Efficiency

Apart from the benefits to patients, the integration of 3D scanning and 3D printing streamlines the orthopaedic brace design and manufacturing process for clinicians. Traditional methods involved laborious manual work, often requiring several iterations and adjustments to achieve an optimal fit. In contrast, the digital workflow powered by 3D technologies accelerates the brace design process, reducing lead times and minimizing waste of materials and resources.

Furthermore, digital records of the 3D scans and brace designs enable seamless communication and collaboration between orthopaedic specialists, therapists, and other healthcare providers. The ability to share and store patient-specific data securely enhances continuity of care and facilitates evidence-based decision-making.

Addressing Challenges and Looking to the Future

Despite the undeniable benefits of 3D scanning and 3D printing technologies in orthopaedic brace customisation, several challenges remain on the horizon. The integration of these technologies into existing healthcare systems may require substantial investments in training, infrastructure, and equipment. Additionally, regulatory considerations and standardization of 3D printing processes in the medical field warrant careful attention to ensure patient safety and product quality.

As the field continues to evolve, ongoing research and development efforts will likely lead to advancements in materials, hardware, and software, further enhancing the capabilities of 3D scanning and 3D printing technologies. Continued collaboration between researchers, clinicians, and technology developers will be critical in optimizing and standardizing these innovative solutions to maximize their impact on patient care and orthopaedic practice.


The fusion of 3D scanning and 3D printing technologies has ushered in a new era of orthopaedic brace customisation, revolutionizing patient care and clinical practice. The precise and personalized nature of these braces addresses the limitations of traditional methods, offering enhanced patient comfort, compliance, and treatment outcomes. For orthopaedic specialists, the adoption of 3D technologies streamlines workflow efficiency and fosters interdisciplinary collaboration. As we embrace these transformative technologies, we can look forward to a future where orthopaedic braces are not merely medical devices but customized, patient-centric solutions that empower individuals on their journey towards recovery and improved musculoskeletal health.

3D scanning and 3D printing technologies support orthopaedic brace customisation

Currently, with the gradual spread of 3D scanning and 3D printing technology in the medical field, several brace studios and orthotic centres at home and abroad have introduced and benefited from the new 3D digital brace customisation process.

In China, there are also specialist workshops like OT4 that offer personalised support services for patients.

Traditional orthotic fabrication involves making a plaster cast of the patient’s body, then turning the orthotic according to the plaster model and later reshaping and polishing it, with problems such as large deformations, inaccurate fixation points and a poor working environment for fabrication.

(Scoliosis orthosis – nylon)

3D printed orthoses vs conventional orthoses

The beauty of technology is that it makes the complex simple.

The beauty of technology lies in having humanity and warmth.

3D digital technology is not an end in itself, innovation and creation that improves human production and life is our ultimate goal!

To achieve flexible production of complex structured products and to bring personalised products into hundreds of millions of homes.

Professional Plastic & Metal Product Custom Services

Contact V1prototype

Contact us now to bring your idea into reality, our professional team will respond you in 24 hours after we get your email.

About V1prototype

leave a message

    Support file types: images, compressed files rar or zip; Size 20mb

    More information related to V1 rapid prototype