WP15 – OrthoScan3D

Orthoses are medical devices designed to enhance performance in individuals with mobility challenges or disabilities. Frequently prescribed to address various pathologies, customized orthoses provide notable advantages in terms of medical functionality and comfort, allowing continuous use over the recommended treatment period.

Adapting the geometric shape to each patient enhances efficacy in immobilization or movement restriction. Additive manufacturing (AM) techniques allow for topological optimization, 4D manufacturing, and multi-material integration, which result in weight and thickness reduction, improved breathability, and controlled flexibility.

AM systems are particularly suitable for customizing wearable and non-wearable devices. Despite their benefits in customization, these systems are not widely applied in the Portuguese healthcare sector. To harness these advantages, it is essential to integrate all related technologies, transforming technical possibilities into real products. Mass adoption of these methodologies—at affordable costs for patients—depends on achieving efficient integration and simplifying production processes.

To advance and implement these technologies in healthcare, this project proposes to develop a comprehensive system that enables one-shot body and limb scanning. The resulting data will be used to design sensorized medical devices, such as orthoses and custom seating, which will then be manufactured through deposition and precision machining for finishing.

All contact materials will be anti-allergenic and suitable for the specific application. Given the niche nature of this field and the usual challenges of market penetration, the project will also prepare market assessment models to support adoption and accessibility.