Healthcare & Medical
Healthcare & Medical
3D printing for orthotics and prosthetics manufacturing
3D printing for orthotics and prosthetics manufacturing
3D printing for orthotics and prosthetics manufacturing
3D printing solutions and technologies can genuinely improve lives—and nowhere is the impact more immediate than in orthotic and prosthetic (O&P) care. Instead of forcing patients to “fit the product,” we design and manufacture the product to fit the patient. From flexible liners for prosthetic sockets to functional foot orthoses, each device is digitally customized to match anatomy, gait, pressure tolerance, and clinical goals—then produced in a fraction of the traditional lead time.
At 3DX, we can produce lightweight parts that are soft where they must be, strong where they should be, and safe for prolonged skin contact (with the right material selection and finishing). We also offer repeatability and consistency, meaning you can reprint the same geometry with minimal variation—crucial for follow-up pairs, replacements, and long-term patient records. Final parts can be dyed or finished to match patient preferences, including discreet tones or bolder, personalized aesthetics.
3D Printed AFO (Ankle-Foot Orthoses)
3D Printed AFO (Ankle-Foot Orthoses)
3D Printed AFO (Ankle-Foot Orthoses)
AFOs benefit massively from digital design because small geometric tweaks can make or break comfort and function. With 3D printing, we can engineer:
- Targeted stiffness: rigid control for drop-foot vs. more dynamic response for energy return
- Comfort features: soft edges, smooth transitions, pressure-relief zones around bony prominences
- Breathability: lattice structures and ventilation cutouts that reduce heat build-up and skin irritation
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Slimmer profiles: lightweight designs that fit better into footwear without bulky trimming This is especially valuable when patients need fast iteration (e.g., discomfort points, growth changes, or activity-level upgrades).
3D Printed KAFO (Knee-Ankle-Foot Orthoses)
3D Printed KAFO (Knee-Ankle-Foot Orthoses)
3D Printed KAFO (Knee-Ankle-Foot Orthoses)
KAFOs are typically heavy and time-consuming using conventional workflows—so this is one of the clearest wins for additive manufacturing. 3D printing allows:
- Weight reduction without losing stability, using reinforced geometries and smart internal structures
- Improved alignment control, especially when the design is built around the patient’s scan and mechanical axis
- Better comfort over long wear times, by integrating relief zones and smoother contact surfaces
Consistent reproduction, helpful for long-term therapy plans or multi-stage rehabilitation
KAFOs can be designed to support a range of clinical requirements—from stability-focused bracing to more dynamic assisted movement—depending on the hinge system and prescribed control.
Below-Knee and Above-Knee Prosthetic Sockets (BK/Transtibial & AK/Transfemoral)
Below-Knee and Above-Knee Prosthetic Sockets (BK/Transtibial & AK/Transfemoral)
Below-Knee and Above-Knee Prosthetic Sockets (BK/Transtibial & AK/Transfemoral)
Sockets are where comfort either happens—or fails. 3D printing doesn’t magically remove the need for proper clinical fitting, but it does give you finer control and faster iteration when comfort, suspension, and pressure distribution must be dialed in. We can 3D print:
- Below-knee sockets with refined trim lines, controlled flex zones, and pressure management around tibial crest/fibular head areas
- Above-knee sockets with tailored proximal contours and stability features based on suspension strategy and limb shape
- Test/check sockets for rapid fitting trials, followed by optimized definitive designs after clinical feedback
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Ventilated or lightweight structures where clinically appropriate, without compromising the load-bearing zones This workflow is brutally practical: scan → design → print → fit → adjust digitally → reprint. Instead of redoing everything, you improve the model and repeat quickly.
3D Printed Hand & Arm Splints (Wrist, Forearm, Braces, and Supports)
3D Printed Hand & Arm Splints (Wrist, Forearm, Braces, and Supports)
3D Printed Hand & Arm Splints (Wrist, Forearm, Braces, and Supports)
Upper-limb splints are a perfect match for 3D printing because comfort and compliance depend on fit and wearability. We can produce:
- Wrist and forearm supports with precise contouring to the patient’s anatomy
- Hand/finger immobilization splints for post-injury positioning and tendon support
- Functional braces designed around movement allowance (where prescribed), not just immobilization
Ventilated, lightweight designs that reduce sweating and skin maceration
You also get a major hygiene advantage: designs can be cleaned easily, and replacement is straightforward because the file is preserved.
3D Printed Protective Masks
3D Printed Protective Masks
3D Printed Protective Masks
We also manufacture 3D printed protective masks for applications requiring facial-fit customization, rapid production, or specialized use cases. These can be designed for:
- Improved face seal based on scan or standardized sizing
- Comfort-enhanced contact surfaces and controlled rigidity for prolonged use
Replaceable filter interfaces (depending on the intended specification)
As with any protective equipment, performance depends on the intended standard and validation approach—so we build to the required fit and functional brief rather than making vague claims.
Cranial Helmets
Cranial Helmets
Cranial Helmets
Helmet molding therapy, or cranial orthosis, is a type of treatment in which a baby is fitted with a special helmet to correct the shape of the skull. If a child is diagnosed with deformational plagiocephaly, brachycephaly or scaphocephaly and is less than 15 months old, cranial remolding may be prescribed to correct the shape of the baby’s head. Today with 3D Printing technology
What we manufacture at 3DX
At 3DX, we manufacture a wide range of O&P solutions including:
- Ankle-Foot Orthosis (AFO)
- Knee-Ankle-Foot Orthosis (KAFO)
- Prosthetic components and sockets (below-knee and above-knee)
- Insoles and foot orthoses
- Upper-limb devices: hand splints, wrist & forearm support, braces and splints
- 3D printed protective masks
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Cranial Helmets
