OST 2023 review: Serial 3D printing is the future of orthopedic products

On hand was iFactory3D’s conveyor belt 3D printer, the One Pro. The device, which has been available for some time, was on display on the exhibition floor. The special feature of the printer: thanks to an integrated conveyor belt and remote control, orthopedic insoles, for example, can be manufactured additively in series around the clock at low cost and without supervision. The use of modern scanning technologies and digital programs in model processing saves time and transitions barrier-free to implementation with 3D printing. Moreover, the digitization of data associated with 3D printing also helps research: working exclusively with 3D digital model data and corresponding patient or user experiences simplifies the analysis of clinical conditions and enables comprehensive conclusions. As a result, widespread problems related to foot health can be identified more easily and treated appropriately. 3D technology thus leads to a win not only for producers but above all for patients, whose needs are always paramount. The fact that the 3D printing method also saves material, and therefore money and time, is a welcome bonus for podiatrists – and the environment.

That’s because, unlike conventional methods, 3D printing achieves a shape by adding material, hence the term additive manufacturing. CNC milling, on the other hand, removes valuable material that often can’t be reused. With the targeted addition of material, 3D printing consumes less of those same materials. Its modernity and conscious use of resources make 3D printing attractive to young workers. Traditional trades such as insole manufacturing are well advised to switch to this technology in order to acquire more young talent for the profession. The younger generation in particular is aware of the need for sustainable activities and is questioning the material-intensive and inefficient methods of traditional production.

Playing into the issue of the skills shortage at iFactory3D is the One Pro’s plug-and-play approach. Switching to 3D printing and the delicate setups involved, as well as researching the necessary materials and software, typically require a great deal of effort in terms of time and or the use of high-priced skilled labor. The latter remain scarce and a solution to this is not in sight. This makes it all the more important for asset manufacturers to focus on making equipment easy to use and manage, with as little additional manpower as possible. With a simple closed-loop system like One Pro, a single employee can keep large production volumes running on their own, and productivity is boosted in the process.

At the show, the Feetneeds and iFactory3D teams quickly realized that there is a great need for end-to-end concepts in the orthopedic shoe (insole) market. Most of the systems on offer are isolated solutions that are difficult to link together. Different software providers hardly harmonize when it comes to interfaces and data transfer. Manually reworking and adjusting the data so that it can be correctly interpreted by the continuing system requires know-how and patience at every step.

The increased interest in closed systems plays into the hands of Feetneeds powered by Plasmics and iFactory3D. Together, the companies offer a model where all parameters, from model development to printing, come from one development and thus communicate seamlessly. Another plus is the ease of implementation of universal scanning software, which is already in use in many places. When you upgrade your production with Feetneeds powered by Plasmics, you get the optimized hardware – the One Pro 3D conveyor belt printer, the associated CAD software for data processing and the necessary filament material – provided without any initial investment. You just confirm to produce a minimum of 250 pairs of insoles per year printed as part of Feetneeds powerd by Plasmics‘ offering. This means you can easily get started with additive manufacturing and quickly benefit from lower unit prices by purchasing larger quantities, as the price per sole is adjusted to your production volume. With larger purchase volumes, you save on individual manufacturing costs. This promotes the potential growth of the manufacturing customer.

iFactory3D’s 3D conveyor belt technology has already reached more than 10 countries, from Switzerland to France and Australia. Podiatrist Akbal Randhawa, founder of The Foot Clinic in the United Kingdom, has been using the One Pro for nearly two years, "3D conveyor belt technology is new to the UK. I make several pairs of orthotics a week, and the One Pro allows me to make them myself quickly and with minimal waste. Without the One Pro, I would have to send the orthotics to a lab and then wait two weeks for them to be made. The orthotics I make replace the devices milled from EVA and even some of the molded plastic orthotics."

Given the importance of 3D belt printing for orthopedics and medical technology, iFactory3D will also be present at MEDICA, which will be held in Düsseldorf, Germany, from November 13-15, 2023, and is one of the largest B2B medical trade shows in Germany. iFactory3D won the MedX@Düsseldorf competition, allowing it to officially represent the city of Düsseldorf at MEDICA.

About Orthopädie Schuh Technik 2023 (https://ost-messe.de)
ORTHOPÄDIE SCHUH TECHNIK is the trade fair specifically for the orthopedic shoe technology industry. Manufacturers, wholesalers and service providers in the sector will find their ideal platform here to present their range of services from the field of therapeutic appliances and aids. The two-day congress with 30 specialist lectures and almost as many seminars offers a complete overview of orthopedic shoe technology and provides decisive impetus for the further development of the trade and the link to related fields of work.

About MEDICA (https://www.medica.de)
MEDICA is the leading trade fair for medical technology, medical imaging, health IT, laboratory equipment and diagnostics. It will take place from November 13-16, 2023 in Düsseldorf, Germany.

Feetneeds by Plasmics (https://feetneeds.at)
Feetneeds by Plamics is committed to insole production with cutting-edge technology. They take a fully integrated approach, combining high-end 3D hardware solutions with optimized and specialized data acquisition and processing, from 3D model creation interfaces to processing and additive manufacturing.