User holding bright pink 3D printed medical orthosis.

andiamo 3d printed ORTHOSIS

/01/ Overview

/01/ Overview

Custom fitted 3D printed orthoses for kids and adults.

The ultra-accurate (±0.5mm) and lightweight (up to 65% lighter than traditional ones) 3D printed custom orthoses from Andiamo are the perfect marriage of necessity and technology. Developed across two offices in London and Gdańsk, these orthoses serve kids and adults across Europe. In fact, Andiamo's Ankle Foot Orthosis (AFO) was the first 3D printed orthosis fully refunded by the National Health Service (NHS) in the United Kingdom. I joined as a design engineer and eventually became the design and engineering lead of our first product standards, AFO, where the permutations of 103 design parameters allow the creation of a staggering 23 trillion uniquely different devices.


(under employment contract)
  • Industrial Design
  • User Studies
  • Mass Customisation
  • Proof of Concept Prototyping (POC)
  • Performance Engineering
  • Design for Additive Manufacturing
  • Technical Documentation



/02/ User testimonies

“I never knew walking could be fun.”

raisa, age 20
walking freely with her first pair of Andiamo orthoses.

“I thought I had reached my limit, my Andiamo orthoses have changed that.”

Jack, age 12
walking without sticks for the first time.

“I give them 100 out of 10, throw my old ones in the bin.”

Umar, age 9
after 4 weeks
Video 1.
A story of Tom, who, after becoming a user of Andiamo orthosis, began breaking his physical barriers.
Video ©Andiamo

/03/ Product line

3D printed Chest Brace, Ankle Foot Orthosis and Hinged Ankle Foot Orthosis.
Orthotic technician opening 3D printed AFO.
Orthotic technician flexing foot wings of a 3D printed AFO.
Line up of different 3D printed orthoses, SMO, AFO, Hinged AFO and more.

/04/ Product breakdown

Font view of a row of 3D leg scans.

Mass manufacturing custom products as unique as each of us requires immense efforts and resources. In the realm of affordable 3D printed orthoses, it is a fusion of material science, biomechanics, software engineering, artificial intelligence (AI), mechanical engineering, and highly empathetic and parametric industrial design. No such efforts can be successful without a methodological approach. This process involves breaking down requirements and products into their constituents and rebuilding them by deeply studying their influence on the whole product and the design and manufacturing process. As the lead of such efforts, I was responsible for planning, conducting, and coordinating joint efforts to create a set of standards and parameters that could later be used by AI.

Breakdown analysis of medical 3D printed orthosis from the industrial design process.Breakdown analysis of medical 3D printed orthosis from the industrial design process.
Figures 3-4.
Example of a simplified breaking down of an orthotic device into its individual components, such as thicknesses, clearances, joints, fasteners, or paddings so they can be examined for their role and functional limits in the overall structure.
Figures ©Andiamo

The implementation of parametric design in the medical device sector necessitates the breakdown, in-depth research, and STANDARDISATION of variables, components, and functions. Only through this process can comprehensive standards and parameters for mass manufacturing be established.

/05/ Ankle Foot Orthosis (AFO) - dorsal wings

The dorsal wings of an AFO device are crucial for ease of donning, doffing, and wearer comfort. They need to be flexible for donning yet strong for holding the foot in the prescribed position. I assisted in planning and executing a comprehensive standardisation study, likely an industry-first, to investigate the influence of geometrical parameters on the performance of 3D printed dorsal wings.

Comparison of 3D printed AFO and conventional AFO.
User testing 3D printed wings of an AFO medical device.
User testing conventional wings of an AFO medical device.
Prototype of 3D printed AFO wings testing.
Figures 5-8.
Examples of good and bad dorsal wings in an AFO device.
Figures ©Andiamo
Fine Element Analysis, FEA, of 3D printed medical orthosis.Fine Element Analysis, FEA, of 3D printed medical orthosis.
Figures 9-10.
Examples of Fine Element Analysis (FEA) of a dorsal wing opening on an AFO device.
Figures ©Andiamo
Fine Element Analysis, FEA, of 3D printed medical orthosis.
Screenshot of CAD models of AFO wings prototypes for mechanical testing.
Examples of 3D printed prototypes of medical device.
Testing on a bench 3D printed prototype of AFO wing.
Figures 11-13.
Examples from over 60 test swatches, from the original pool of 240 digital models, were 3D printed for mechanical and usability studies on AFO dorsal wings.
Figures ©Andiamo

/06/ Ankle Foot Orthosis (AFO) - heel lift

Heel lifts in ankle-foot orthotic devices are often used to modify patient gait parameters for healthier walking. As the leader and main investigator of this study, I had to consider not only the minimum and maximum lift angles and the integration of the heel with the main orthosis geometry but also its impact on shoes, including local wear and excessive weight loading. Additionally, I addressed concerns related to the total device weight and the ease of removing unsintered 3D printing powder from internal cavities to prevent it from affecting the patient's shoes.

Perforation in the heel rise of an 3D printed AFO, medical device.
Perforation in the heel rise of an 3D printed AFO, medical device.
Figures 14-15.
Examples of perforations used to lower the weight of an additional AFO heel.
Figures ©Andiamo
Figure 16.
Side view of different heels with varying angles, sizes and style.
Figure ©Andiamo
Side view of different AFO heel rise design.
Examples AFO heel prototypes made using FDM 3D printer.
Prototype of a heel for AFO for testing.
Figures 17-18.
Sample of 3D printed AFO heels using SLS and FDM technologies.
Figures ©Andiamo
Visualisation of medical orthosis with a perforated heel rise.
Figure 19.
Example of a CAD models of an AFO heel.
Figure ©Andiamo

/07/ Hinged Ankle Foot Orthosis (AFO)

The addition of hinge to an AFO frees one plane of joint rotation while still keeping others locked so clinicians do not have to unnecessary limit the joint. The process of designing a hinged AFO is complex, and if unsuccessful, it can lead to unhealthy patient gait, painful skin pinching and wear, frequent servicing, or even a shortened device lifespan. In the study I assisted in planning and executing, we analyzed all factors influencing hinged AFO design and conducted numerous tests to derive best practices and guidance for orthopedic technicians and software engineers developing AI to automate the process.

Close up on 3D printed mechanical test pieces of AFO hinge casing.
3D printed mechanical test pieces of AFO hinge casing.
Close up on the industrial design of a medical orthotic device.
Figure 20-21.
Mechanical test prototypes for AFO hinge, assessing functional limits.
Figures ©Andiamo
Sice by side view of the industrial design of a medical orthotic device.
Close up into the inside of a 3D printed Hinged AFO.
Figures 22-24.
3D printed hinge-AFO with good split line and alignment of rotation planes.
Figures ©Andiamo

Recognition for Andiamo's advancements in the Orthotics & Prosthetics field extended beyond the segment, earning it the title of London’s most innovative technology startup.

Close up at the back of a blue 3D printed medical orthosis.

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