Two-fold Opportunity.
Customized production at scale.
Personalize
Make Things Unique
- Unique geometries on a massive scale
- Mass customization
Short & Mid-production Runs
Faster & Less Waste | Scalable & Low Risk
- Demand, then produce
We partner with notorious Additive Manufacturing players to ensure your parts are meticulously produced with every print job.
Improved patient outcomes with 3D-printed wearable orthotics & prosthetics.
At Proto3000, we can produce medical and prosthetic devices with fairly complex geometries that are more effective, lighter and more cosmetic. Whether you need a completely unique prosthetic or require short or mid-production runs, we can help you!
Better for Everyone
Why produce insoles, orthotics and prosthetics with 3D printing?
Manufacturers
Reduce manual labour ♦ Consistent repeatability ♦ Higher accuracy ♦ Ease to scale.
Clinicians
Faster patient turnaround ♦ No need for plaster molds ♦ No molds shipping ♦ Less fitting adjustments.
Patients
Better fit, less bulky ♦ Lightweight & breathable devices ♦ Comfortable for daily usage
An End-to-End Solution
From production to post-processing, we have you covered!
RAW
DYE
PAINT & OTHERS
How the process works.
Connect & Consult
Our team of experts works with clinicians and medical experts to design & develop the best orthotics and prosthetics.
Design & Development
We then use the provided inputs and powerful industry-leading software tools & materials to help you produce innovative assistive devices.
No more conventional orthopedics!
3D Print | Manufacture
We recommend options from a range of different additive manufacturing processes and materials that meet your application requirements and performance objectives.
Inspect & Ship
Thanks to our technological capabilities, we can print out directly the final products. Our production team rigorously checks each part for conformity and accuracy.
Applications
- Wearables and soft-touch elements
- Gaskets, seals, masks, belts, plugs, and tubes
- Protective sports equipment
- Padding, dampers, cushions, and grippers
- Soles, splints, orthotics, and prosthetics
- Insoles
- Knee braces
- Wrist & Back supports
- Collars
Materials
Based on each project, our Service Bureau can recommend the best materials on the market that withstand the required properties and functionalities. See below a list of some of the most commonly used powders in the Prosthetics and Orthotics industry.
Formlabs® Nylon 11
Material: Ductile, high-impact
Nylon 11 Powder is a high performance, bio-based nylon material for functional prototyping and small batch production.
Specs
- Ultimate Tensile Strength: 49 MPa
- Tensile Modulus: 1.6 GPa
- Elongation at Break (X/Y): 40%
- Flexural Strength: 55 MPa
- Notched Izod: 71 J/m
- Heat Deflection Temperature (HDT) @ 1.8 MPa: 46ºC
Application
- For parts that need to bend or resist impact
- Impact-resistant prototypes, jigs, and fixtures
- Thin-walled ducts and enclosures
- Snaps, clips, and hinges
- Orthotics and prosthetics*
Technology/Process
- SLS (Selective Laser Sintering)
Formlabs® TPU 90A
Material: Tough SLS Elastomer
TPU 90A Powder provides the perfect balance of flexibility and strength, allowing you to create durable prototypes and end-use parts that are both safe for the skin and withstand daily use.
Specs
Material Properties*:
- Ultimate Tensile Strength: X/Y: 8.7 MPa; Z-axis: 7.2 MPa
- Tear Resistance: X/Y: 66 kN/m; Z-axis: 39 kN/m
- Elongation at Break: X/Y: 310%; Z-axis: 110%
- Shore Hardness: 90A
Certifications/Tests:
- Samples printed with TPU 90A powder have been evaluated in accordance with ISO 10993-1:2018, and have passed the requirements for the following biocompatibility risks:
- ISO 10993-5: 2009 Non-cytotoxic
- ISO 10993-23:2021 Non-irritant
- ISO 10993-10:2021 Non-sensitizer
*Material properties may vary with part geometry, print orientation and temperature.
Application
- Wearables and soft-touch elements
- Gaskets, seals, masks, belts, plugs, and tubes
- Protective sports equipment
- Padding, dampers, cushions, and grippers
Technology/Process
- SLS (Selective Laser Sintering)
Nylon 11 (HP High Reusability PA 11)
Material: Polyamide 11 (Nylon PA 11)
Thermoplastic polymer, known for its toughness, chemical and high-temperature resistance. It is commonly used to produce functional prototypes, end-use parts, and tooling.
Specs
- Tensile Strength:
- 50 MPa/7250 psi (XY axis)
- 50 MPa/7250 psi (Z axis)
- Powder Melting Point (DSC): 202° C / 396° F, ASTM D3418
- Particle size: 54 microns, ASTM D3451
- Bulk density of powder: 0.48 g/cm³, 0.017 lb/in³
- Density of parts: 1.04 g/cm3, ASTM D792
- Biocompatibility – meets USP Class I-VI and US FDA guidance for Intact Skin Surface Devices
Application
- Healthcare
- Prostheses, Insoles
- Consumer Goods
- Sport goods
- Snap fits
- Living hinges
- Industrial
- Education
Technology/Process
HP Multi Jet Fusion (Powder Bed Fusion)
Nylon 12 (HP High Reusability PA 12)
Material: Polyamide 12 (Nylon PA 12)
HP 3D High Reusability PA 12 is a robust thermoplastic that produces high-density parts with balanced property profiles and strong structures.
Specs
- Powder Melting Point (DSC): 187° C or 369° F, ASTM D3418
- Particle Size: 60µm
- Bulk Density of Powder: 0.425 g/cm3 0.015 lb/in, ASTM D1895
- Tensile Strength: 30 MPa
- Elongation at Break: 20%
- Young’s Modulus: 1600 MPa
- Charpy Impact Notched Test: 35kJ/m²
Application
- Consumer goods and electronics
- Low-high volume production
- Rapid prototyping
- Manufacturing aids
- Tooling, end-of-arm tooling, robotics
- Medical
- Porthotics, prosthetics
Technology/Process
HP Multi Jet Fusion (Powder Bed Fusion)
Cost-effectiveness
- Less wasted material
- Less labour work
- Fewer reiterations
Fast Printing Speed
3D printing technologies offer faster patient turnarounds due to our technologies' capabilities.
Biocompatibility
We use biocompatible materials such as TPU or Nylon.
Light & Comfortable Products
Advanced structures like lattices and meshes reduce the device’s weight and increase breathability while being resistant and performing well. 3D-printed orthotics & prosthetics are less bulky, fit better and are developed for daily usage.
Freedom of Design
Additive manufacturing allows the creation of custom products, individually-tailored for each patient. 3D-printed orthotics & prosthetics are less bulky, fit better and are developed for daily usage.
Mass Customization
Customized production at scale of personalized products or short and medium production runs.
Check out Formlabs’ whitepaper on how to 3D print rigid insole shells using the Selective Laser Sintering technology.
Fill in the info below to access the document.
Check out Formlabs’ paper about the mechanical performance analysis of 3D-printed and traditionally manufactured rigid insole shells.
Fill in the info below to access the document.