iOrthotics was founded in 2009 and is located in Mackay, Queensland, Australia. It is a custom-made orthopedic insole for pediatricians. The company uses digital manufacturing processes to create custom orthopedic solutions that bring unique benefits to pedicure clinics and their customers. iOrthotics has invested $ 100,000 in research and development, and is also working with the University of Queensland to develop custom orthopedic solutions.
Challenge
Foot orthopaedic expert IanGoodchild said, "The goal of any orthopedic insole is to support and correct the foot and improve the function of the foot. The traditional manufacturing method is to use Paris plaster, which is both inaccurate and cumbersome. Orthopedic insoles are often not wearable. Therefore We need better solutions. "
Traditional orthopedic techniques start with making molds. Usually, the patient's feet need to be wrapped in plaster during production. This can both make the patient uncomfortable and cause fear. It is also imprecise because the mold is usually cast under non-loaded conditions. In addition, it requires a podiatrist to have a "wet chamber" dedicated to casting plaster molds.
After casting into a mold, conventionally, a subtractive manufacturing method was used to make orthopedic insoles. Orthopedic insoles are either milled using a CNC router or cast and ground using thermoformed plastic. Both methods require skilled artisans and extensive finishing. This process is slow and usually requires multiple running-in to obtain satisfactory results.
In addition, the equipment used in traditional manufacturing, including milling and grinding machines, takes up a lot of space. Perhaps most importantly, the subtractive manufacturing process is also very wasteful. It usually requires 1.5 kg of material to make a pair of corrective insoles weighing only 100 grams.
Solution
Mr Hartley said, "As a fast-growing company, we need to innovate manufacturing processes to meet market demand. It is impractical to continue to use subtractive manufacturing processes, producing only 30 products per day. 3D scanning and 3D printing enable us There is an opportunity to improve the quality of orthopedic insoles, while also expanding our production scale and reducing waste caused by traditional methods. "
3D scanning
The first step in creating a digital solution is to enable 3D scanning so that plaster molds are no longer needed.
A foot doctor working with iOrthotics can use 3D scanners to obtain patient foot data. This technology avoids the disadvantages and challenges of traditional molds and provides more accurate measurement data for correcting insole designs.
2.Custom software
In addition to 3D scanning, the iOrthotics team needs a way to capture the scanned data and convert it into CAD files that can be 3D printed. They developed custom software to automate much of the work involved in the design of printable orthopedic insoles.
3D printing solutions
Finally, they needed a 3D printing solution that met their strength and durability requirements while also being economically viable.
HP Jet Fusion 3D 4200
iOrthotics reviewed HP's MultiJetFusion (MJF) 3D printing technology and found that the materials and products used are superior to other methods. In addition, they found that these devices take up much less space than traditional manufacturing equipment and enable mass customization of insoles at a faster rate. These features meet the growing needs of iOrthotics' business.
iOrthotics 3d printing insole
At the end of 2017, iOrthotics became the first commercial customer in Australia to purchase the HP Jet Fusion 4200 3D printing equipment. With the equipment in place, they have all the tools they need to complete the digital production of custom orthopedic insoles.
Result
Thomas Leahy, Technical Development Manager, iOrthotics, said: "The digital workflow involves a lot less steps. We receive the scan data from the foot doctor, load it into our custom software, and then 3D print, clean, and glue it to the top cover. That's it. From the beginning to the end, traditional orthopedic insole manufacturing methods often take 2 weeks. We usually take only 3-5 days from scanning to shipping. "
Thanks to HP's 3D printing solutions for superior productivity, iOrthotics' output has tripled, from 30 orthopedic insoles per day to about 90 per day. As demand increases, they can further increase production. In addition, because the new digital workflow is more automated and less labor intensive, iOrthotics can open additional production locations where needed, allowing them to expand their businesses to meet almost any demand at home and abroad.
Product quality has also greatly improved. From a materials perspective, extensive research and testing conducted by iOrthotics and the University of Queensland have shown that orthopedic insoles produced by HP JetFusion 3D printing equipment are 40-60% stronger than those produced using conventional polypropylene grinding.
Design freedom from additive manufacturing is also important. iOrthotics produces products that are more flexible and comfortable. This has produced very positive results for its end users. In addition, iOrthotics is able to label their orthopedic insoles for clinics at design time, help them market their businesses, and build long-term relationships with customers.
iOrthotics HP 3D Printing process
Mr Hartley said, "HP's multi-jet fusion 3D printing technology makes mass customization possible. The ability to mass-customize parts has brought about a technological revolution. All industries will undergo change in the fourth industrial revolution, but may not have manufacturing So significant. IOrthotics has made a positive change to adapt to this technological revolution. "
iOrthotics_3D Printed Orthotic_Grinding
iOrthotics customers and everyone else in the world can benefit from additive manufacturing because it will reduce material waste and lower customization costs. In the orthopedic insole industry, subtractive manufacturing techniques typically waste 90% or more of the materials needed to make the finished product. Because HP's 3D printing solution reuses waste materials, iOrthotics estimates that very little material is wasted.
With HP's multi-jet fusion 3D printing technology, iOrthotics is able to create products that are lighter, stronger and more accurate, helping patients reduce pain. At the same time, they pioneered a scalable business model that could help more people get treatments faster and cheaper.