In the last five years we have seen a very quick development of 3D acquisition technologies, modeling and production of manufactured goods (CAD / CAM). A striking example is the "3D Printing" that has supplanted many work processes, replacing in certain processes even the more recent CNC. In the delicate Biomedical industry, for both developers and technology users, the rapid development created the fear to invent or adopt systems that soon would be overcome by more innovative ones. Paradoxically, there was a kind of paralysis in the circulation of these technologies, creating a wide gap between research and commercial application. This phenomenon made possible only the production and sale of very expensive CAD-CAM systems that have proved not to be successful.
For the difficulties of the labor process, there are not many Orthopaedic Workshops that produce corsets for Dysmorphisms, because in order to offer such a service, workshops must be equipped with suitable premises for the acquisition of the trunk (plaster room) and other the necessary services (shower, bathrobe, slippers, etc.).
We can summarize the classic work process of Orthopaedic workshops:
1. Plaster bandages moistened with water are enveloped around the trunk with the aid of a metal cage acting as a support,
2. When the plaster bandages dry, the shell pinstripes is cut longitudinally and the patient is free to escape the negative casing,
3. The shell is filled of plaster, obtaining a copy of the patient's torso. This first phase lasts on average 1 hour and causes discomfort to the patient especially in younger ones.
4. The positive pinstripe must be modeled in other room with rasp and elbow grease.
5. Subsequently, a polyethylene slab properly heated in a large oven is turned around the plaster block weighing about 50 kg and submitted to negative pressure through a pump.
6. Next step: moulage (cutting) of the model brace.
Given the manual nature of the current techniques of acquisition and production, an experienced orthopedic technician can build on average 1 max 2 busts a day depending on the model.
Do not ignore the costs for plaster disposal that this type of work requires.

Innovation: Designing orthotic device through 3D modeling
The system we have been refining and testing for 2 years, through the use of 3D scanners sensors, allows the acquisition of the body and the creation of a virtual model, which already now is an innovative process reducing working times and costs

The model, manipulated digitally with advanced sculpturing instruments, is directly "correct", until it assumes the ideal shape. The phase of the digital modeling is done through a software allowing a precision and a percentage of error very close to 0%, unlike the classical machining which involves the work of man rasping the plaster block.

Implementation of the physical model
Double road (3d cad cam or print directly)

cad Cam
At this point of the process the virtual model is transformed into a physical one by a 3 or 4-axis CNC starting from a polyurethane foam block. Then, you can build on the latter the final orthotic device, through the previously illustrated classic workmanship.


3d printing
Today our team is able to create braces printed directly by a 3D printer.
At this point of the process, the virtual model is transformed into a physical model through 3D printing.

Some examples of braces printed with 3D printer

Summary of the benefits of an acquisition system and 3d Printing
1. Small spaces for the acquisition, a box 2x 2m.
2. the time required for the acquisition is 1/4 of a second with the possibility to operate corrections already at this stage.
3. Discomfort reduced for the patient.
4. modeling time reduced at 30 min
5. accuracy of the system improved with better control on the corrective forces with commercial software
6. best brace-patient compliance.
7. Increased productivity for orthopedic technicians.

For braces printed with 3D printing
7. No waste of material with possibility to recycle the brace (pla)
8. Ability to model the bodice with heat gun after it is built
9. costs reduced significantly
10. Lower weight
11. Elimination or reduction of the reinforcements
12. Artifact aesthetically better

Technology adds a further value to the business because the entrerprises results more flexible, efficient and competitive, getting able to succeed in global markets.

Italy is a country characterized by small and medium-sized enterprises, where digital technologies can actually mark a change in the ability to compete and bring wealth to the territory where they operate. By sharing experiences and a real cooperation between business and research, a culture of innovation may rise bringing growth and development.