CASE STUDY - iORTHOTICS

THE CUSTOMER

INDUSTRY SEGMENT: HEALTHCARE | Prosthetics and orthotics

APPLICATION VERTICAL: HEALTHCARE | Prosthetics and orthotics

Established in 2009 in Mackay, Queensland, iOrthotics has become Australia’s premier resource for podiatrists who seek custom-made orthotic devices for their patients. Their customizable orthotics are designed with patients in mind and to make life easier for both clinicians and patients. iOrthotics ensures that all orders are manufactured and sent out within three to five business days.

In addition to using the latest digital foot/cast scanning processes, computer-aided design (CAD), and computer-aided manufacturing (CAM), iOrthotics is leading the industry in 3D printing orthotic devices.

During the past 18 months, iOrthotics' lab has investigated materials, software, hardware, and design processes to ensure their podiatry clients will receive a product that is not simply equal, but superior to traditional polypropylene.

Most notably, iOrthotics has been working with the Research Fellows from the University of Queensland’s School of Mechanical and Mining Engineering (Advanced Materials) to test the stress and strain properties of different materials.

3D PRINTING MAIN BENEFITS

CHALLENGE

iOrthotics needed to triple production capacity within a six-month period, and they were unable to use current manufacturing methods to scale quickly.

SOLUTION

iOrthotics engaged University of Queensland’s Advanced Manufacturing and Engineering departments to test and benchmark all materials and to innovate and implement new technologies such as 3D printing.

WHY 3D PRINT

CUSTOMIZATION

3D printing allows for the production of orthotics that result in higher customization, superior aesthetics, and higher reproducibility.

WASTED MATERIAL REDUCTION

Using subtractive methods during the material removal process results in nearly zero waste in an industry known for producing significant waste.

COST

The cost per part rivals subtractive manufacturing methods.

WHY HP MJF

PRODUCTIVITY

Productivity is increased compared with other 3D Printing technologies. Using HP Multi Jet Fusion technology, output has increased fourfold to more than 100 pairs per day.y.

FINAL PART

Parts are printed nearly finished and require very minimal postprocessing. Cost savings are significant in terms of skilled labor and the ability to scale production.

MECHANICAL PROPERTIES

Newer, stronger materials are used in production that result in superior orthotics and aesthetics.

SUSTAINABILITY

iOrthotics is committed to a more sustainable future for the industry and the environment. They have moved away from unsustainable subtractive manufacturing processes and now lead the industry in additive manufacturing (3D printing). With 3D printing for rigid orthotics, iOrthotics has been able to transition to produce nearly zero waste, compared with traditional polypropylene devices.

When a podiatrist chooses EnviroPoly, waste is reduced by more than 99% compared with orthotic devices made from milled polypropylene. By improving their manufacturing methods, iOrthotics is able to create a more environmentally friendly and sustainable product. Not only are their 3D printed orthotics good for the environment, they are lighter, thinner, and stronger than ever.

WASTE PRODUCED

SUBTRACTIVE MANUFACTURING

PER PART 1.4 kg

YEARLY PRODUCTION

10,000 parts

PER YEAR

14,000 kgs

HP MJF

PER PART <5 g

YEARLY PRODUCTION

10,000 parts

PER YEAR

50 kgs

MATERIAL

HP 3D HR PA 12

POST-PROCESSING

Bead blasting

Dyed in black


FINAL PART: Customized

FOOT INSOLES

WHAT ARE FOOT ORTHOTICS PRESCRIBED FOR?

  • Lower costs and shorter lead times compared with Injection Molding
  • Superior part strength and durability compared with stereolithography
  • 15% cost reduction compared with SLS
  • Vastly improved surface finish compared with fused deposition modeling


VIEW THE PRINTERS USED

HP Jet Fusion 3D  300/500 Printers
HP Jet Fusion 3D 4210/4200
CONTACT US TO LEARN MORE


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