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The O&P industry has entered a transformative era where 3D printing is no longer a futuristic concept; it is a proven technology that is already widely used across clinical practices globally. A July 9 news item on The O&P EDGE website highlighted a study conducted in Switzerland comparing 3D-printed orthoses to low-temperature thermoplastic devices. This research clearly demonstrated the value of 3D printing for post-traumatic applications, where these lightweight, patient-specific devices offer excellent comfort and efficiency.
But this is only the first wave of what 3D printing brings to our field. To fully understand its potential, it is important to look beyond low-temperature thermoplastics, devices that are primarily used in post-traumatic or post-surgical situations and are often fabricated directly at the point of care. The more profound transformation is happening in the realm of custom-made O&P devices, especially those fabricated from high-temperature plastics for chronic and neuromuscular conditions.
In these complex cases, traditional manufacturing is a highly labor-intensive process requiring plaster casting, multiple adjustments, and several patient visits. Here, 3D printing has already proven to be a disruptive force. An interventional feasibility study conducted at the University Hospital of Amsterdam (Journal of Rehabilitation Medicine, May 2024) compared 3D-printed custom hand orthoses with conventionally fabricated devices for patients with chronic hand conditions. The results were striking:
- Production time was reduced by more than 50 percent with 3D printing.
- Manufacturing costs dropped significantly. The median cost was €187 (about $217 USD) for 3D-printed orthoses versus €398 (about $462 USD) for traditional ones.
- Clinical outcomes, including hand function, activities of daily living, and quality of life, were comparable across both types of devices.
- And crucially, 79 percent of patients preferred the 3D-printed orthosis, citing its comfort, fit, and lighter weight.
These findings confirm what many clinicians and manufacturers are already experiencing: 3D printing enables highly personalized care, reduces production bottlenecks, and allows orthotists to spend more time on clinical decision-making rather than manual fabrication.
As the technology matures, its advantages are being leveraged across a range of use cases, from post-operative wrist splints to complex spinal bracing, demonstrating not only feasibility but also scalability. The orthotics field is now moving past the question of whether 3D printing works to exploring how far it can take us.
This is not about replacing traditional methods entirely; rather, it’s about integrating digital workflows and additive manufacturing where they make the most impact. In doing so, we can offer patients solutions that are not only clinically effective but also more comfortable, sustainable, and accessible.
The future of O&P is being shaped today. And digital is part of it.
Louis-Philippe Broze is the CEO of Spentys. He can be contacted at lp@spentys.com.
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