Massons chose to acquire the HP Jet Fusion 5200 Series 3D Printing Solution – the first of its kind installed in Australia – based on its ability to deliver precision, speed, and design flexibility. Supported by EVOK3D's technical guidance, benchmark parts, and workflow simulations, Massons successfully transitioned to a digital workflow.

Key technological highlights

At the heart of Massons' innovation was a shift in both material and mindset.

They chose HP 3D High Reusability PA 11, a bio-based, skin-friendly nylon that struck the perfect balance between mechanical strength and flexibility. More than just durable, it was sustainable—a conscious step toward an eco-friendlier future, without compromising on performance or patient safety.

But the innovation didn't stop with the choice of material. Massons introduced a new level of refinement in the post-processing phase—where precision meets patient comfort.

Finishing techniques that made a difference

Vapor Smoothing with AMT's PostPro SF100 delivered a polished, seamless surface for a professional finish. Bead Blasting refined the texture and removed rough edges for safer, smoother wear.

Comfort, thoughtfully engineered

Moisture-wicking foam liners maintained dryness and comfort throughout the day, enhancing durability and long-term wear.

Velcro attachments provided a secure, adjustable fitting, enabling patients to personalize tightness with ease.

Design, too, received a thoughtful upgrade. These weren't just medical devices anymore – they became personal. From ventilation cut-outs for breathability, to variable wall thicknesses that matched the contours of the body, every detail was reimagined for both function and feel. Add in personalized graphics and custom patterns, and each orthosis became as unique as the person wearing it.

Case in focus: A custom CTO for Sydney Children's Hospital, Randwick

When a young patient at Sydney Children's Hospital, Randwick needed a Cervical Thoracic Orthosis (CTO), the team at Massons saw an opportunity to do something better – not just for this child, but for the future of orthotic care.

Collaborating closely with the hospital's orthotics department, they set out to create a lightweight, breathable, and more comfortable CTO using cutting-edge technology. What followed was a transformation of both process and product.

Instead of traditional manual moulding, they used a digital 3D scan and CAD design, allowing for precise, patient-specific wall thickness and a streamlined fit. Strategic ventilation cut-outs improved airflow, while custom design details enhanced comfort.

The shift to HP Jet Fusion 3D Printing cut down manual labour by over 60% and reduced material waste dramatically – from nearly 45L to just 375ml.

The result: a high-performance orthosis tailored to the patient's needs, built faster, cleaner, and with far greater comfort.

To truly understand the difference, Massons partnered with EVOK3D for a time-and-motion study, and the results spoke volumes.

By shifting to 3D printing, manual labour time dropped by 60%, cutting down from nearly five hours to just one hour and forty minutes per orthosis. Production also became more efficient, with up to six sockets printed in a single HP MJF build, dramatically boosting throughput.

Perhaps most striking was the environmental impact: plastic waste was reduced from approximately 45 litres to only 375 millilitres per device—a meaningful evolution toward sustainable practices.

But beyond the numbers, the biggest win was human. With less time spent on fabrication, clinicians could refocus their energy where it mattered most—on patient care.

With demand for 3D-printed orthotics and prosthetics rapidly growing, Massons is gearing up for its next chapter— one driven by innovation, local impact, and industry leadership

Armed with Australia's only TPU processing station and equipped with vapor smoothing, Massons is uniquely positioned to lead the way. Their roadmap is bold and future-focused:

And in collaboration with HP Additive Manufacturing Solutions and EVOK3D, they're set to explore the next generation of materials—unlocking even more potential in performance and patient comfort.

Through HP's Multi Jet Fusion technology and their partnership with EVOK3D, Massons Healthcare has not only digitized their production process but also redefined patient care in orthotics. Their innovative approach sets a new standard for functional, aesthetic, and comfortable orthoses—created faster, more sustainably, and closer to home.