Structure Optimized 3D-Print Orthoses

The goal of 3DPrint2Fiber is the development of a process chain for a fast and inexpensive production of individualized ankle foot orthoses with a stiffness, which is adaptable by thermoplastic fiber tapes to the needs  of the patients.

Many patients, which are suffering from a drop foot, wear Ankle Foot Orthoses (AFOs) to support the affected leg. The current production process of AFOs is not only expensive and time consuming, but also allows only little post-processing and subsequent customization to the patient. In order to ensure inexpensive and individual patient care, the entire process chain of the production of AFOs has been re-established within this project. The developed process chain consist of five steps:

  1. Recording the affected leg by use of mobile 3D scanner on site
  2. Adjusting the basic design of the AFO to the anatomy of the patient
  3. Creating a detailed CAD-Model of the designed orthosis
  4. Producing the AFO using a rapid manufacturing process (3D printing)
  5. Reinforcement of the AFO by thermoplastic fiber tapes

The re-established process chain is based on a newly developed basic design of an AFO. The stiffness of this AFO can be individually adapted by applying fiber tapes. To reach an easy placement process of the thermoplastic fiber tapes, a handy device has been developed within this project. This device enables the orthopedic technician to place the fiber tapes individually to the requirements of the patient.



Ulrich Blass

Wiss. Mitarbeiter Bauteilentwicklung

Telephone: +49 631 2017 321



The project “3DPrint2Fiber – Development of a Hybrid Process for the Production of Personalized and Structurally Optimized 3D-print Orthoses On Site” is funded by the Federal Ministry of Education and Research (BMBF) within the “KMU-innovativ” program
(funding reference 13GW0196).