Personalized care at scale: 3D-printed orthotics and prosthetics for humans and pets
Overview
Hello, everyone. This is David Soriano from HP Additive Manufacturing Solutions (AM), segment manager for Healthcare Solutions. Welcome to our orthotics and prosthetics booth, also known as O&P. HP has worked in this industry for years, developing solutions with partners, and today we lead the market in orthotic and prosthetic applications.
Regulatory Milestones
A major milestone this year is regulatory recognition in the US, where 3D-printed parts are now considered equivalent to traditional parts. This will drive adoption and scale globally.
Key Applications
One of the fastest-growing applications is cranial devices for infants, printed with HP Multi Jet Fusion (MJF) using PA 12 White. These devices are worn 23 hours a day, so they must be comfortable and breathable. Lattice structures and ventilation holes ensure comfort while enabling treatment to correct head deformities.
Another key application is ankle-foot orthoses (AFOs), which combine rigid materials for performance and flexible materials for comfort. 3D printing allows lightweight, precise, and repeatable designs that improve patient experience.
Prosthetics and Veterinary Applications
In prosthetics, we see similar benefits. For example, a prosthetic socket combines flexible internal layers for comfort and rigid external layers for strength, supporting patient weight while ensuring a perfect fit. The veterinary space is also growing, with orthotic and prosthetic devices for pets, including wound protection and mobility aids.
Innovation Showcase
Finally, meet Bob—a humanoid fully printed with HP MJF—showcasing prosthetic legs, arms, orthotics, and helmets. All devices are patient-specific, designed for individual needs. HP AM remains committed to advancing this segment, reducing costs, and scaling adoption worldwide.
Abstract:
At Formnext 2025 visitors discovered how HP's 3D Printing technology supports the development of personalized orthotic and prosthetic (O&P) applications. The demo showed a variety of medical and veterinary use cases—from infant cranial helmets and adult epilepsy protection gear to animal wound care and orthopedic braces—highlighting how HP's 3D Printing Solutions enables comfort, functionality, and scalability.
Detailed summary:
The HP booth featured a diverse collection of applications that addressed both human and veterinary needs.
Visitors saw the following applications:
- Ankle-foot orthoses (AFOs) that combine flexible TPU interiors with rigid outer structures to deliver both comfort and support.
- A prosthetic socket with an adjustable tension wheel demonstrated how 3D printing can enhance usability and fit.
- A two-in-one infant cranial helmet, designed with an internal shell that adapts to a child's growth, offering a progressive, non-invasive treatment approach.
- Veterinary applications from Wimba included wound care devices made with TPU, designed to treat open injuries in pets. These donut-shaped components were demonstrated on a demo dog showing how 3D printing supported animal rehabilitation.
- A protective helmet for adults with epilepsy, designed to prevent injury during seizures and reduce self-harm. The helmet featured coverage for the ears and mouth to address specific behavioral risks.
- Hand and arm braces, representing new customer collaborations and expanding HP's portfolio of functional, patient-specific devices.
- A personalized neck collar used to stabilize the head and neck after injury or surgery.
This demo illustrated how HP's Additive Manufacturing solutions enables healthcare providers and veterinary professionals to deliver personalized care at scale—improving patient outcomes while streamlining production.
To learn more about HP 3D Printing Solutions for O&P, visit the webpage here.
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