HP MULTI JET FUSION LEADS TO LOWER COSTS IN ORTHOTICS PRODUCTION
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Crispin Orthotics creates orthotic devices that can prevent, correct, and/or relieve symptoms of various ailments. Each patient’s individual condition requires an individual solution, which is why their orthotics service covers everything from assessment and fitting to aftercare. Crispin works with the National Health System (NHS) and private patients throughout the United Kingdom.
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THE CHALLENGE
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An ankle foot orthosis is primarily designed for individuals who have a neurological condition such as multiple sclerosis or complications arising from a cerebrovascular accident (CVA), which affect muscle control in the lower limbs, particularly in the dorsiflexion muscles.
Within the orthotics industry, it is not possible to create a dynamic ankle foot orthosis without using carbon fiber. Carbon fiber is non-adjustable, not environmentally friendly, difficult to finish, and very expensive to produce.
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SOLUTION
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Crispin replaced carbon fiber with HP 3D High Reusability (HR)1 PA 12 material and HP Multi Jet Fusion (MJF) technology.
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Crispin Orthotics specialists have designed this orthosis to prevent the foot from dropping downward during the swing phase of gait. The switch to HP MJF technology resulted in the following benefits:
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INDUSTRY
Healthcare
SECTOR
Prosthetics and orthotics
MATERIAL
HP 3D High Reusability PA 12
POST-PROCESSING
Bead blasting
Dyed in black
Matt lacquer sealant
SIZES
X: 1.18 in / 3,0 cm
Y: 8.07 in / 20,5 cm
Z: 0.079 in / 0,2 cm
VOLUME
1.57 in3 / 25,7 cm3
COST
$0.87 / 0,71€ per part
$0.62 / 0,51€ variable cost
$0.25 / 0,20€ fixed cost
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Lower costs. Compared with devices made from carbon fiber, HP MJF–produced devices cost 50% less to produce.
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In addition to the control element of the orthosis, Crispin designed the leaf spring to incline forward to preclude the use of a calf strap, thus making the device more cosmetic and lightweight.
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1. Based on using recommended packing densities and compared to selective laser sintering (SLS) technology, offers excellent reusability without sacrificing mechanical performance. Tested according to ASTM D638, ASTM D256, ASTM D790, and ASTM D648 and using a 3D scanner for dimensional accuracy. Testing monitored using statistical process controls. HP Jet Fusion 3D Printing Solutions using HP 3D High Reusability PA 12 provide up to 80% post-production surplus powder reusability, producing functional parts batch after batch. For testing, material is aged in real printing conditions and powder is tracked by generations (worst case for reusability). Parts are then made from each generation and tested for mechanical properties and accuracy.
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