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3D Printing News Briefs: February 28, 2020

In today’s 3D Printing News Briefs, AMUG has announced the recipients of its two scholarships, Ultimaker is marking a milestone with a new online marketplace and new Cura features, and a company has created a revolutionary 3D printed helmet to help children with flat head syndrome.

AMUG Announces Scholarship Recipients

The Additive Manufacturing Users Group (AMUG) just announced the two recipients of its annual scholarships, who will now be recognized at the AMUG Conference in Chicago next month. The Guy E. Bourdeau Scholarship is awarded to one college student with a passion for AM, and this year it went to Katherine (Kate) Schneidau, who is pursuing a master’s degree in mechanical engineering at the University of Louisville. Chris Kaminsky, the Lakeshore Fab Lab manager at Muskegon Community College, received the Randy Stevens Scholarship, which is awarded to one educator who emphasizes or focuses on AM. Schneidau learned about SL, DLP, FFF, SLS, DMLM, and other methods of 3D printing through her engineering co-op, and taught others how to use the equipment, in addition to developing new process parameters for plastic and metal materials. Kaminsky makes 3D printing and design accessible to others by co-founding the MI3D organization, and is also a guest speaker about the technology.

“I’m so excited to announce that Ms. Schneidau and Mr. Kaminsky have accepted the scholarships and will attend AMUG 2020,” said Brett Charlton, chair of the AMUG Scholarship Committee. “Once again, the pool of applicants was strong, and their experiences were vast. I’m certainly in awe—the experiences of our 2020 applicants in AM are astonishing, and it bodes well for AM’s future! The talent pool made it a challenge to select the right individuals, but both of our recipients are amazing and truly deserving of this honor.”

Ultimaker Introduces Marketplace and New Cura Features

To celebrate its milestone of preparing 2,000,000 print jobs per week through Cura slicing software, Ultimaker launched a new online Marketplace, along with the release of Ultimaker Cura 4.5 and its additional features. Cura now has over 600,000 active users a month, and at the end of 2019, it was preparing twice as many print jobs per week as it had in 2018. Ultimaker Marketplace gives users access to plugins for standard software platforms, while the latest software release connects the Marketplace to Cura with new cloud functionality, which associates the plugins and optimized printing profiles directly with the user.

“Ultimaker Cura is continuously powered by its open source community and dedicated in-house software team. We see our user database is rapidly expanding every day with new students, makers and professional users. Where one user is more eager to manually tweak and test every setting available, others want to fully integrate 3D printing into existing workflows,” said Ultimaker’s CTO Dick Moerkens. “I am proud of our open approach and agile development strategy, which allows us to fully streamline and simplify the 3D printing workflow now and in the future.”

3D Printed TiMband Air Helmet

UK company Technology in Motion specializes in plagiocephaly (flat head syndrome) solutions for babies and children – namely, remolding helmets that are 3D printed so they’re more lightweight and comfortable. According to research, orthotic helmet treatment is the best way to treat severe head shape deformity, and the customizable TiMbandAir helmet (also known as the Talee in EU countries) is made with patent-pending bio-responsive technology for a better, more breathable fit – allowing the head to correct as it grows over four to six months. It has a unique three shell construction: the inner layer is a soft easy-clean liner to minimize sweating, while the mid-layer is important for shock absorption and offers flexible, gentle pressure, and the outer layer holds shape, gives strength, and provides protection. Thanks to 3D printing, these shells are also thinner than in other similar helmets, and the helmet features a breathable design to promote ventilation. Technology in Motion takes a photographic 3D scan of the baby’s head, and 3D printing, provided by partners at Invent Medical, ensures a custom fit. In 2018, the company received the prestigious Red Dot: Best of the Best design award for its recently launched TiMbandAir helmet, available in Technology in Motion clinics across the UK.

“We are extremely proud of the TiMbandAir helmet. We have had an amazing response so far, with almost 50% of parents opting for the TiMbandAir since its launch,” said Steve Mottram MBAPO, Managing Director of Technology in Motion. “We understand the distress, uncertainty and confusion parents undergo and we are excited to offer parents an improved form of flat head syndrome treatment for the future.

Discuss these stories and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

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Operation Namaste Making 3D Printed Molds for Prosthetic Aligners in Nepal

Last January, Certified Prosthetist-Orthotist (CPO) Jeff Erenstone, the Chief Technology Officer of Create O&P, decided to leave the company he co-founded in order to continue advancing and improving clinical and prosthetic care in the developing world.

Jeff Erenstone fitting a prosthetic liner on an amputee’s leg

In addition to treating patients in his upstate New York clinics, he has now focused all of his attention on Operation Namaste, the non-profit organization he co-founded that is working to ensure amputees around the world have easy access to comfortable prosthetic care.

According to the organization’s website, it helps “determined people achieve by providing tools and support to Orthotic and Prosthetic practitioners in Nepal and beyond.”

Operation Namaste has worked on several helpful projects, such as hosting a summit on prosthetics and orthotics, setting up Camp Namaste for Nepalese children with limb differences, helping a Paralympic hopeful play basketball, and completing the Nepal Warrior Trek, where a team of amputees and business owners traveled to the country to raise awareness and financial assistance for victims of the 2015 Nepal earthquake.

Its latest project is SILC (silicone interface liner comfort) Solutions, which is a system for fabricating silicone liners locally. In October, Operation Namaste volunteers took a trip to Kathmandu, Nepal to test out the new program, which will work to improve prosthetic care – using 3D printing – in developing countries.

“Part service trip and part trek, this trip featured a team of prosthetists, a physiotherapist, and an amputee peer counselor who toured the beautiful country of Nepal, visiting several prosthetic clinics along the way and putting on an educational summit for Nepali practitioners discussing the latest care techniques,” the website stated about the organization’s Nepal Trek 2019.

Prosthetic liners go between an amputee and their prosthesis in order to increase mobility and comfort…which is great for patients in high-income countries with either medical insurance or the money to pay for them.

SILC Solutions prosthetic liner

Erenstone said, “Without prosthetic liners, amputees would not be summiting the Himalayas, returning to active-duty military service, and competing against able-bodied athletes in Olympic sports.”

Unfortunately, these liners are not readily available, or are too expensive, for most amputees in low-income, developing countries like Nepal.

Demonstration at educational conference in Nepal

Operation Namaste’s new SILC Solutions method uses CAD-designed, 3D printed molds to create standard-sized silicone liners. Compared to typical liners, which can cost upwards of $200, the sustainable ones created by the organization will cost less than $50 to fabricate – making them far more accessible to amputees in developing countries.

Erenstone mixing silicone to make a liner in Nepal

Erenstone has firsthand experience in seeing the positive difference that a quality prosthetic liner can make in the life of an amputee, especially in places like Nepal.

“I’m really excited for this project take off in Nepal, and beyond. Our goal here was to make liners affordable, accessible, and sustainable, and I think we are achieving that,” said Erenstone.

ROMP (Range of Motion Project), a Colorado-based nonprofit organization with dovetailing goals, is partnering with Operation Namaste to help achieve the goal of improving prosthetic care all around the world.

“Gel liners are just not within reach for most people in developing countries,” said Eric Neufeld, the chair of the board at ROMP. “This has been a limiting factor in the quality of care for amputees.”

3D printed liner mold

During Operation Namaste’s recent trip to Nepal, the team of volunteers successfully tested out the new SILC Solutions program, determining that it was possible to use 3D printed molds to make lower cost prosthetics anywhere. The organization plans to finalize its SILC prosthetic liners ahead of another planned trip to Nepal in spring 2020, where volunteers will deliver necessary materials to fabricate the liners and train practitioners on the process.

Discuss this news and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below. 

[Images: Operation Namaste]

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Interview with RESA’s Glen Hinshaw on 3D Printing Shoes

Glen Hinshaw’s path to 3D printing is more circuitous than most. He used to ride in professional cycling circuits, was on the US Postal cycling team, founded a circuit board transport company, was a registered tax planner, was the manager of F1 driver Scott Speed, managed world tours for the Rolling Stones and U2, worked for the US Olympic Committee, managed an outdoor signage company as well as a games company. Along the way, Glen founded esoles that became a pioneer in 3D scanning soles using conventional means to manufacture them in stores and founded a leading custom bicycle fitting center. For nearly 15 years now Glen has been trying to make the in-store manufacturing of orthotics and custom shoe soles a reality. He came to 3D printing not because he was interested in the technology but because it could potentially make his dream of custom footwear for everyone a reality. With his startup RESA, he is trying to realize in-store manufacturing of 3D printing, and we spoke about his journey there.

How did you get started in 3D printing? 

I wanted to improve the way custom insoles were made. After spending over a decade using traditional injection molding and CNC milled processes, we learned about AM and began to refine the process for our specific use case. That included designing custom internal structure forms, shaping the way the insole is built to improve performance and reduce production time. Ultimately we got the entire process down to under an hour, Using a process that we can use right there in the retail environment.
What does RESA do now?
Deploys on-premise 3D foot scanning / Custom design / 3D printing systems to retail and medical locations. Using our own unique scanning technology and use our own custom high speed FDM machines.We provide customized orthotic insoles under $140 USD; ready-to-wear in 1 hour or less.

What partners are you looking for?

Banking on retail in the 21st century is a fairly radical idea for many investors. What we have seen is making insoles onsite is really popular with customers, met with excitement and return orders well beyond what we ever imagined. With AM and our FDM processes, our margins can support more growth, with a much lower capex.

For this to grow, we need Investor(s) and industry leaders in both hardware and software technology, who are not afraid to embrace retail 2.0.
Our industry talk about ‘on demand, custom, on-site manufacturing’ as the wave of the future, people are surprised that we have already successfully proven high margins and customer demand far greater than expected for our custom footcare and footwear.

What is the advantage of a 3D printed insole?

Thankfully it’s easy for people to understand the advantage of 3D printing insoles, it’s perhaps one of the most simple use cases. We all know that 3D printing is perfect for making every part unique, and the best insoles are ones that are individually fitted to not just the customer, but to their activities and even their specific footwear. Its an obvious match! .

And of course we have the data to back this up. We didn’t just offer our product to the public and see sales, we had a national trial program that sold more than 50,000 pairs of insoles!

What is the potential? 

At the most customer focused level, there is the opportunity for almost anyone to get access to a level of footcare that before many would have found prohibitively expensive. And when over 39% of adults experience foot pain, we know thats not a small problem or a small market.

At the same time, retail must transform, those who do not embrace Retail 2.0 will not survive. Resa is a company offering a product that engages customers and fulfills their needs in a way that is actually made more effective by being face-to-face. We are also able to use the data that customers share with us to make them Happy, not just for insoles, but for other products in the footwear space.  With the most highly-evolved, most reliable footcare technology ever developed, we believe the world market can all benefit from our foot shape imaging and custom footwear/foot care products and services, over 14 billion feet worldwide.
Why is it important to 3D print in the store?
Quite simply because having an end-to-end, face-to face process is much better at driving customer engagement.
Because of direct customer interaction, we are able to capture far higher quality scans, that lets us provide a better product, with far higher satisfaction rates. And along the way we get to educate and entertain the customer, learn from them and better tailor our products to them. At the core we aim to be customer focused this means interacting with your customers, there is no better way to do that than in store. And it’s the best customer experience if at the end, you can hand them their product.
You made insoles before through other means, what is the difference?
The conventional ways to make insoles mentioned earlier have lots of limitations, either they are cheap but not custom, or you can have semi-custom and more expensive, or fully custom but you wait 2-6 weeks and it’s very expensive (not to mention the waste and mess if you are milling foam!) 3D printing lets us offer fully custom at point of scan, but at a much lower price, with no mess and in under an hour.
What materials are you using?
We use a custom TPU blend, and in the future we will use more recycled or even biodegradable polymers.
What is holding back 3D Printing in footwear? 
Understanding how and when to use 3D printing. There is already wide use of 3D printing for tooling, but it takes time for designers and engineers to learn what works and what doesn’t when it comes to 3D printing for end use consumer products.


What is holding back 3D printing generally?

It’s not technology… Now don’t misunderstand. We need new and better 3D printing technology, but just as in footwear, it’s the lack of knowledge around how to successfully exploit the process that is holding this industry back.

“Can you 3D print this?”, is an easy question. “Should you 3D print this?” is a much harder question.
What advice do you have for a company that wants to manufacture with 3D printing? 
Don’t fall into the trap of thinking that 3D printing is a magic black box that just produces finished shapes. It’s a manufacturing process, and like any process you need to understand how and when to use it.
What technology developments are you excited about?
We are already working on research to better understand how to change the way we build our insoles, by using machine learning and AI we can change the internal structure of our insoles to improve comfort, better absorb impact and even improve long term health outcomes for our customers.

And the Team at Resa care about our long term impact on the environment, 3D printing does produce less waste, but long term we need to not just use more recycled and re-processed polymers. We need to move to polymers that are actually part of the natural environmental cycle, like bio-polymers. We are all excited to see the fruits of the investments in new bio-plastics and other biodegradable materials for 3D printing.

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Twikit’s Twikbot Brings Mass Customization Using 3D Printing To Prosthetics and Orthotics

Twikit is a Belgium based startup that makes mass customization software. The firm created parametric software that can be used to, within well-defined parameters, make unique 3D printed products. For BMW, for example, the company created a tool that would let Mini owners customize polymer car parts to their liking. Mini owners can now get 3D printed customized outside panels with their own text or parts that let their LED lamps spell out their names. By letting a person customize something, ensuring that this can be visualized in the browser and then also actually be a file that can be manufactured Twikit ties unique inputs to makable things. Twikit’s software takes the potential of 3D printing to make unique things and turns it into something that many can use (within limits).

Twikit has just released its Twikbot software platform for Prosthetics and Orthotics. Now Twikit can not only be used for customized car parts or parts of consumer electronics but also for medical applications. With the Twikbot platform, companies can now create workflows where unique scan data gets turned into a 3D printable file. Defined limits of the 3D printing process, essential structural elements, and part constraints can be defined in advance. Once this has occurred, and if the 3D scan is good, the path from 3D scan to 3D file for printing is automatic. We’ve seen a lot of movement on implementing more and more prosthetics and orthotics in 3D printing. These are increasingly being made using FDM (FFF), SLS and MFJ technologies but so far there hasn’t been an automated customization package that could mass customize 3D prints for all platforms. We interviewed Twikit’s CTO Olivier den Deken about a new development that the firm has just released.

What does Twikit do for orthotics & prosthetics?

3D printing is a cornerstone technology in the digital transformation of the orthotics and prosthetics market. It also enables to design better products with a perfect fit. In order to obtain a working flow, different dots need to be connected. In comes Twikit.

Twikbot engine takes care of product customization starting from a 3D scan, creating the perfect shape and fit. The cloud software automates your design process and delivers a unique production-ready file. Additionally, Twikit provides design engineering and integration services to implement the technology.

How does it work?

It is important to note that this solution has been developed for Certified Prosthetists Orthotists. CPO’s can create a custom 3D product by using the easy-to-use interface. After choosing the product type, they are able to upload a 3D scan. The CPO sets all required parameters (e.g. adaptations of the 3D scan, measurements) and corresponding points on the scan. Based on this information, the product template (e.g. a knee brace) is automatically reshaped to fit the patients scan.

Finally, the product (e.g. the knee brace) can be finetuned with aesthetical options such as patterns and color.

The CPO can review and order when she is ready. The application runs in the cloud for full scalability and is easily accessible on all devices (including tablets).The Twikbot platform will now create a production-ready-file in the cloud. The production files can be directly connected with the Order Services Module which is used to distribute the parts and parameters to the internal or external manufacturer.

How does it save money?

With the solution in place, either the manual production flow and/or the flow to manually design each unique digital model becomes obsolete. This saves many hours of manual labor and it eliminates errors. Through further automation of the order process, files can be processed quicker resulting in a scalable solution for the offerings of Orthotic and Prosthetic brands.

What will happen with the medical scan data of my patient?

The production file based on the medical scan is assigned with an encrypted code for further tracking and handling. No personal data is stored or spread unless consented to by the patient.

What is the output in terms of files?

Twikbot exports production ready files for additive manufacturing (.stl) or vector files (cutting) depending on the product.

What 3D scan data can I input? and how?

3D scan data can be obtained from 3rd parties or from handheld tablet compatible scanners like Occipital’s Structure Sensor. The 3D scan can be uploaded in the applications where further operations like scan checkup and manipulation can be done.

 

 

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Crispin Orthotics Purchases HP 4200 from Europac 3D for 3D Printing Orthotic Devices

In 2016, 3D printing, scanning, and inspection business Europac 3D, headquartered in the UK, was named a UK Channel Partner for HP, which means that it’s responsible for the sales and servicing of all of HP’s 3D printing equipment in the country. Recently, Crispin Orthotics contacted Europac 3D in search of a new 3D printing and CAD software package that would be able to keep up with the demand for orthotic devices, while also speeding up production and lowering 3D printing costs, and the company suggested HP’s 4200 Multi Jet Fusion 3D printer for the job.

“The HP Multi Jet Fusion 4200 is able to accurately mass produce bespoke orthotic devices, which in turn can cut costs and speed up production times,” said John Beckett, the Managing Director and Founder of Europac 3D. “Crispin Orthotic’s use of the HP’s Multi Jet Fusion printer is indicative of how additive manufacturing is revolutionising the orthotics industry.”

[Image: Sarah Goehrke for 3DPrint.com]

Crispin is a top HCPC registered clinic specializing in producing and maintaining orthotic devices, and has already worked with HP in the past. By making a further investment in its MJF technology, Crispin is able to produce parts that are strong and flexible enough to be made into orthotics that can endure a human’s everyday movements.

HP’s 4200 MJF can produce parts up to ten times faster, and at a 50% cost-per-part reduction, when compared to other SLS 3D printing systems. This reduced cost and increased speed means that Crispin will be able to 3D print hundreds of personal, customized orthotics in just 12 hours.

Crispin tested out its new HP 3D printer by pairing it with Siemens NX CAD software, featuring topology optimization, so its technicians could add strength to important areas and make designs more lightweight. In addition, the software is also capable of organizing multiple 3D parts so they nest, or perfectly fit, together on the print bed. This capability decreases the number of print jobs, which also lowers cost and increases speed.

“3D scanning and printing has revolutionised the speed and quality of parts we’re able to produce for clients.  Having the ability to create a bespoke devise that is lightweight, durable and accurate to 0.2mm has obvious benefits to the user. The business also benefits from the speed of 3D printing parts as well as cost savings of approximately 40% on each part by removing the need for multiple components in the supply chain and assembly,” said Mark Thaxter, Managing Director of Crispin Orthotics.

“Using 3D scanning and printing also provides greater freedom on the design of products particularly those with complex geometry.  Having the ability to vary the thickness of the device in certain parts also allows us to produce devices not possible with current methods of manufacturing.”

Crispin used its new HP MJF 3D printer, and its Siemens NX CAD, during a recent project. The combined technologies made it possible for the company to create a 3D printed arm orthotic with an integrated elbow joint and an attachment at the end, which makes it possible to pair up prosthetic devices with it. The device was 3D printed in a single part out of a durable but lightweight nylon material.

The sample parts that Crispin 3D printed on its new HP 4200 MJF system passed all of the necessary tests. But even more impressive is that the parts all had homogeneous strength in the three separate build axes, which just goes to show that build orientation does not have any negative impacts on the quality or strength of 3D printed parts.

Discuss this news and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

[Images provided by Europac 3D, unless otherwise noted]

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Interview with Prosthetist and Orthotist Brent Wright of LifeEnabled on 3D Printing Prosthetics

Amidst the hubble and bubble of optimism, money and growth, there are also people doing good things with 3D printing. Open source prosthetics are one of the most exciting areas of 3D printing. Here is an area where widely available desktop printers and industrial systems can be used to make patient-specific prostheses, braces, and medical assistive devices. These can also be made on location and very cost-effectively. 3D printing has the potential to completely transform the production and distribution of these devices. The idea is great but what is the reality like in the field? In order for that to happen a few talented individuals will have to be the tip of the spear and actually implement these technologies. One person who is pushing inexpensive 3D printed prosthetics is the prosthetist and orthotist Brent Wright. He is bringing the industry knowledge and training that he has to 3D printing and implement it in technology and capital deprived areas worldwide. Brent founded LifeEnabled a nonprofit that provides prosthetics to people worldwide. Brent also works for EastPoint Prosthetics and Orthotics where he honed his craft. Brent and LifeEnabled are an inspiration and you should help them push the envelope for helping.
What is LifeNabled?
“LifeNabled is a non-profit organization that specializes in creating high quality, low cost, durable, and new prostheses for the developing world.  We believe that everyone missing a limb deserves to have mobility and access of a prosthesis.”
Why should I work with you?
“If you love people and like to see individuals that otherwise would not be able to walk get a prosthesis there is a place for you supporting LifeNabled.”
What kind of companies are you looking to partner with?
“We take our partnerships very seriously and they come from a diverse background.  It truly takes all types of people and companies to make LifeNabled successful.   For example we have a partner that does baseball training and loves what we do and gives LifeNabled exposure to their clients.  We have a company that has convenience stores that provide exposure at the stores as well as access to business consulting via the CEO.  We have another company that works with donors if they want to donate stock to us. None of these companies have experience in prosthetics but they believe in our mission.”
What does a prosthetist do?
“I always like to break down prosthetics and orthotics in a word picture.  Most people have seen the classic movie Forest Gump.  Forest Gump wore orthoses and Captain Dan wore prosthetics.
An orthotist works with someone with all their extremities to provide correction or support to specific part of the body.
A prosthetist works with a person that is missing a part of their body.”
When did you start using 3D printing and why is it so relevant for you??
“I started printing in 2016. 3D printing allows me to reach people in the developing world with a prosthesis without the need to build a large and expensive fabrication facility.”
What is holding 3D printing back in your area?
“Currently, it is materials.  Many of the materials are just not strong enough compared to traditional fabrication and when you make them strong enough they are quite heavy.  I see a lot of promise though with filament manufacturers jumping into extruding PolyPropylene and other innovative new materials.”
What 3D printers do you use?
“Depends on the application.  I have a Raise 3D printer that is highly modified so I can print lots of materials.  I use Filament Innovations machines to print large nozzle and large volume objects.  I use a Lulzbot Taz 6 and Mini’s for detail parts with more resolution.  Lastly, I use my Blackbelt machine for interesting shaped prostheses that traditionally would require a lot of support.”
What materials do you use?
“I use a little bit of everything but have settled on CF PETG and PETG for most applications. I see a lot of promise for the Polypropylene though.”
How could 3D printing materials be improved for you?
“I really think it is a combination of materials and machine.  The closer we get in strength to traditional lamination the better off we are.  A lot more work needs to be completed on how the environment plays a roll in getting a good print.”
What do you think of FDM vis a vis MFJ and SLS?
“I love MJF I am not familiar with SLS but know that the cooling time is an issue with both however MJF allows you to cool parts in another chamber.  The parts are amazing and strong and the resolution is incredible.  The parts are definitely more expensive but the price is coming down.  FDM is still the most cost effective way to print but in my opinion, the reports generated on the MJF machines about how the printer performed and the consistency makes the most sense when we decide to make an end use product.”
Do you think that 3D printing will fundamentally change your field?
“Fundamentals are fundamentals, I think prosthetists are the best in the world creating one of cost effective prototypes.  The rules for comfort and alignment do not change but materials and fabrication styles change. I am looking forward to getting soft materials and hard materials in the same prosthesis. I am looking forward to mass customization that is cost effective.”
Will patient specific braces and orthoses be the norm?
“On upper extremity orthoses, it will be the norm.  Lower extremity orthoses will become more mainstream as we gather data on durability.”
How cost effective is using 3D printing compared to traditional methods?
“For prosthetics, the economics almost work compared to traditional fabrication.  On the orthotic side, it is less work to print the items however the costs are higher when compared to the price we get paid for a given device.  I foresee those costs getting better over time though.”

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Indian Startup Shapecrunch: An App to Let you Get Custom Fit 3D Printed Insoles

Insoles and orthotics generally are looking to be the next area where 3D printing will play a role. As with hearing aids and dental crowns a custom shape needed to fit a patient perfectly can cost-effectively be created through 3D printing. Usually, 3D printing is best at rather small items and insoles are a newer large size than the mass customized things that have been 3D printed thus far in their millions. Insoles have as an advantage however that they’re very flat so require few layers to print, improving the business case significantly. I find it strange that we pay hundreds of dollars for shoes that only come in a handful of sizes. Things such as orthotics and custom insoles can be more costly still. It is clear at this point that 3D printing can provide us with the accuracy, strength and performance needed to endure as a working insole. Whats more with variable density insoles different points of the foot could have different densities through different infill which will give you performance that conventional insoles lack. It is also clear that scanning and 3D scanning could give many people access to custom-made insoles. What is not clear is how to do this and who will succeed in the space. Jabil and Superfeet, Wiiv, Indian startup Shapecrunch thinks it may have the answer by combining 3D printing with scanning using your phone.  We covered Shapecrunch earlier when they first came to our attention in January, Can they succeed where others have failed? We interviewed Nitin Gandhi the CEO of Shapecrunch to find out more.

How did you get started? 

Every 1 in 4 people has some foot problem related to biomechanics such as Flat feet, Plantar Fasciitis etc. Every 30 seconds a diabetic foot is amputated in the world. Moreover, the foot related problems are responsible for back, neck and knee pain. Still getting anything custom made for a foot is a huge challenge. The process of making custom shoe inserts (or insoles) is very manual, has huge setup cost, and takes 30-45 minutes of time for any doctor.

I’m flat-footed, and in 2015 went through the experience of getting an insole.  When the insole came out it was not so good. At that time, since I was already running a 3D printing company, I along with his partners who are mechanical engineers Jatin and Jiten founded Shapecrunch. Later Arunan, a Biomedical engineer also joined them.

Shapecrunch digitized the complete process of making custom foot insoles with 3D Printing and a Computer Vision algorithm.

Doctors use Shapecrunch’s free app -available on android and iPhone to take just 3 pictures of patient’s foot, add patient’s bio and upload a prescription. Shapecrunch using its smart proprietary algorithm converts the images into a 3D model of the insole, which is then 3D printed. The process of taking images and using the app takes just 7 minutes.

For the technology, Shapecrunch did clinical research with the Rehabilitation wing of All India Institute of Medical Sciences (AIIMS) and for a bigger trial, also got a grant from BIRAC.

Shapecrunch started selling in the market in early 2017. So far more than 2000 patients are wearing Shapecrunch’s Insoles. Because everything is remotely done with app, any doctor/patient can download the app, click foot images and prescription pic, Shapecrunch can create custom insoles for many people. As the data is being stored digitally, the patients can order another pair anytime. Every 1 in 4 customers orders another pair for different shoes within 6 months.

What 3D printing technology do you use?

We use FDM 3D Printing technology. All machines are assembled by us so that they can print flexible material perfectly.

What materials do you use? 

Shapecrunch uses flexible 3D printed material for making your customized insoles. Thermoplastic polyurethane (TPU) is any of a class of polyurethane plastics with many properties, including elasticity, transparency, and resistance to oil, grease and abrasion.The upper layer is made from PORON®, a breathable, shock-absorbing material which cushions the foot and has anti-microbial properties to keep feet feeling fresh and healthy.

Whats the workflow for me as a customer?

We are having alliances with podiatrists all across the world who can use our technology to scan patient’s feet, upload prescription and we design and 3D print the insoles. Customers can either go to our alliance partners around their area or can download our app and our in-house team which has orthotist, physio and orthopedic looks at the feet.

What is the benefit for me as a consumer?

We do advance customization which is not possible with traditional ways of making insoles. The computer vision algorithm gives us the boundary curves and machine learning provides us with the inner curves we also take into account age, weight, height, pain areas of the patient. With the machine learning algorithm, we get a variable density profile which goes into making the file 3D printing.

How long do the orthotics last?

Orthotics easily last for up to 2 years for moderate use and 1 to 1.5 years for athletes and heavy users. We do provide a 6 months warranty.

How do you partner with the orthotics community?

As of now, we are participating in medical conferences and exhibiting our product and technology. So far, almost all the podiatrists and physiotherapists care a lot about how it can solve their patients’ problem. We also focused a lot on that.

What kind of ailments are you targetting?

Shapecrunch is making Custom insoles for Flat Feet, Supination, Plantar Fasciitis, Diabetic Foot, Corn and Callus, Leg Length Discrepancy, Knocked Knee and other biomechanical related problems.

 

Where do you wish to roll out the product?

We are already growing fast in India and Singapore and have 50+ clinics using our technology. We are starting in the US soon and plan to have it as our primary market.

Will you integrate sensors into it?

Yes, It’s already under development we are launching it in next 3 months for doctors for diagnostic purposes and as an additional tool for analysis. Later we plan to introduce a consumer version as well.

What about variable density insoles?

All our insoles are variable density. Density at different areas is determined from a variety of parameters such as age, weight, height, pain areas etc.

Will everyone wear these?

More than 2500+ people are wearing shapecrunch’s insoles for foot problems, for sports, marathoners and some just for comfort. For each of our customers, a fully customized solution has been provided to improve biomechanics. So definitely, it should be worn by everyone who needs them.

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Father Takes Up 3D Printing, and Founds New Company, to Create Son’s Custom Orthosis

Some of the most heartwarming aspects of the 3D printing industry involve the people who do everything they can to develop and provide affordable 3D printed prosthetics to people who need them the most. Just in time for Father’s Day, Formlabs has shared a beautiful story about a dad who worked tirelessly to help his young son walk on his own…and ended up helping others along the way.

Cerebral palsy (CP) causes more than 17 million people around the world to have limited control of their own bodies. Seven years ago, Nik, the son of Matej and Mateja Vlašič, was born one month early, and due to difficulties during childbirth, suffered brain damage that led to the diagnosis of CP, and an inability to stand or walk on his own.

To help CP patients walk, many doctors will prescribe standard orthoses meant to correct spine and limb disorders. Patients can purchase pre-made orthotics, and some can even be slightly modified to better fit the patient, but it’s not easy to use one device to help with several symptoms, and they can even lead to skin irritation and pain.

Custom orthoses, CNC machined based off of a plaster or foam box impression, generally fit better, but the cost can be astronomical, even with insurance, and delivery can take weeks. On top of that, children outgrow them quickly.

Matej, who has an engineering background, said, “Based on my knowledge, I knew that a piece of plastic could not cost so much money.”

Matej has worked hard all of Nik’s life to help him move on his own, even using ski boots to stabilize his ankles when he got older.


“When you’re looking at your child, you instinctively know what to do in order to help him. When Nik was unable to turn on his side, I decided to build a ramp so that he could easily flip on his belly. When he found out that this was fun, he was trying to do it all by himself,” Matej said.

“He instantly felt confident, and you could see it in his eyes that he loved it and that he wanted to progress. This is what kept us going.”

Unfortunately, Nik’s short Achilles tendon and low muscle tone kept him on his toes.

“He was afraid of walking because his feet were in a really bad position,” said Petra Timošenko, Nik’s physiotherapist. “If he had tried to walk longer like that, he would have injured the bones and the joints.”

Matej knew he had to find a better way to help his son.

“The lack of comfort and high price combined with all the cons were enough that I decided to do something about it. I didn’t have the solution at that time, but I wanted to find a better way to design it,” Matej said. “I was just trying to help my son the best possible way.

“I didn’t know how orthoses are produced currently, so I was able to look outside of the box.”

He had heard of 3D printing, and after conducting some research, determined that the technology was accurate enough to create a properly-fitted orthosis. One of the benefits of 3D printing, especially in the healthcare field, is its ability to design customized products at a more affordable cost, and Matej was confident he could create a custom, 3D printed orthosis that would give Nik the correction and support he needed.

After a few attempts, Matej successfully digitized Nik’s feet, learned 3D modeling, and spent the next six months researching and experimenting, and eventually developed an innovative workflow, which starts with placing the patient’s feet, in the corrected, standing position, on a vacuum bag.

An iPad-mounted structure scanner scans the footprints from the bag, while the feet are also 3D scanned from above, and the data is merged and cleaned up into an accurate representation. The custom orthosis is designed right on the 3D scanned foot in CAD software, and then 3D printed in high resolution on a Form 2 3D printer with Durable Resin.

The first 3D printed prototype reached almost to Nik’s knee and kept him from walking freely, so Matej got to work on the second iteration, creating a prototype that fit inside a regular shoe. Finally, a successful prototype was created.

“In two or three days he was walking, and we were not needed to take care of him so that he doesn’t fall anymore,” Matej said. “The change was immediate, it was unbelievable.”

Nik’s orthosis is barely visible.

Just how braces align teeth, the 3D printed orthosis keeps Nik’s foot in the corrected position. It’s best to use orthoses at a young age, as children’s bodies can adapt while they grow. Physiotherapy also helps to strengthen ligaments and muscles.

“When he’d been using the orthosis for two or three months, for the first time, I saw Nik smiling,” said Timošenko. “After four or five months, he started to become faster and faster. His steps became longer, and his walking more smooth. He actually started to dance.

“Now I can do much more sophisticated exercise with him. We can run on a treadmill, we can jump, because I know that his feet are in the right position and I can’t cause any deformation to his bones or joints, that might, on the long term, require an operation to correct. If he didn’t have this orthosis, his feet would be in danger.”

Matej created four versions of Nik’s 3D printed orthosis.

“The first version gave him confidence and stabilized him. The second version improved his overall walking smoothness,” Matej explained. “Then the third helped him get better posture, and that’s when he really started to enjoy the walking and started to play around. The fourth orthosis corrected his right foot that was off the center of his body, so now he’s able to stand with his feet together in a straightened, upright position.”

After looking at the workflow, and measuring Nik’s feet with and without his 3D printed orthoses, certified orthotist and prosthetist Dejan Tašner knew that Matej had created a novel solution. He is able to make an affordable custom orthosis in less than 24 hours, and the devices are also comfortable.

“3D printing allows us to create orthotics with different thicknesses in different areas. We can apply a more thick area where it’s needed and minimal thickness to the areas where correction is not required,” Matej explained. “This is not possible with current solutions.

“Orthoses don’t need to hurt, only without pain can the children accept them.”

Matej and his wife decided to certify the workflow, which is now patent-pending, so the process and components will meet standard requirements for medical devices and allow for clinical trials. Matej quit his job to focus on 3D printed, patient-specific 3D printed children’s orthotics full-time and, together with Mateja, Tašner, and Timošenko, formed a new company called aNImaKe.

“At the moment, we are testing with several patients with different pathologies from age three to 11,” Tašner said. “We already see improvements in terms of biomechanics, which is the main goal. But also, crucially, a positive change in sentiment that the parents see in the daily life of their children because they need to feel comfortable to use the orthosis often enough to improve their walking.”

aNImaKe hopes to expand the technique to other parts of the body, such as a hand brace that helps young CP patients spread their fingers.

“We want to enlighten others in the medical industry about the tools that are available today to provide better options to the children,” Matej said. “Orthotics should be built for a person, and should treat only the symptoms, not be standardized solutions that put them in boxes.”

Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts below. 

[Source/Images: Formlabs]