3D-printed orthosis
Custom orthoses, 3D printed from a scan
A custom orthosis used to start with plaster and hours of hand work. With 3D printing it starts with a scan: software designs a device that fits one patient, and an industrial printer makes it. This page explains how it works, what Gero3D makes for clinics today, and what is still in development.
scan · print · heal
What it is
What is a custom 3D-printed orthosis?
An orthosis is an external device that supports, aligns or immobilizes part of the body. Casts, splints and ankle-foot orthoses (AFOs) are all orthoses.
A custom orthosis is made for one patient. Traditionally that means molding material by hand over the limb, or over a plaster model of it. A custom 3D-printed orthosis is designed from a 3D scan of the limb and produced layer by layer on a 3D printer, so the same digital file can be checked, adjusted and printed again.
The digital workflow
Scan, design, print
At Gero3D the whole chain runs from one app at the clinic.
- 01
Scan
The limb is scanned with the Gero app on an iPad in under two minutes, accurate to about 1 mm.
- 02
Design
The software finds anatomical landmarks and fits the cast to the patient automatically, in about 40 seconds instead of about 45 minutes by hand.
- 03
Print
Certified production partners print the device on industrial 3D printers under ISO 13485 processes.
- 04
Fit
The device reaches the clinic within 3 days, and the clinic team fits it to the patient.
What we make
Gero3D orthoses today, and in development
| Device | Status | |
|---|---|---|
| Personalized casts | Short Arm, Thumb Spica and De Quervain casts, each designed from the patient's scan. About 60 g, vs. 1.5 to 2 kg for plaster. Water-resistant, open lattice, removed without a saw. | Available to clinics. About the 3D-printed cast |
| ONE Splint | Ready-made 3D-printed wrist splint in three sizes, for the first visit until the custom cast arrives. | Available. Registered with AMAR, listed with the U.S. FDA. About the splint |
| O&P devices, including AFOs | 3D-printed orthotics and prosthetics for the lower limb. | In development, not yet available. What the research shows |
Gero3D operates a quality management system under ISO 13485:2016, certified by the Standards Institution of Israel (certificate 1123048). More than 500 patient treatments have used the Gero platform. Treatment decisions are always made by the treating doctor.
FAQs
Questions about custom 3D-printed orthoses
What is a custom 3D-printed orthosis?
An orthosis is an external device that supports, aligns or immobilizes part of the body, such as a cast, a splint or an ankle-foot orthosis (AFO). A custom 3D-printed orthosis is designed from a 3D scan of the patient's limb and produced on a 3D printer, instead of being molded by hand over the limb or over a plaster model.
How is a custom orthosis made with 3D printing?
In three steps. The limb is scanned with a 3D scanner, software turns the scan into a fitted digital model, and an industrial 3D printer produces the device. At Gero3D the scan takes under two minutes on an iPad, the cast design is generated automatically in about 40 seconds, and the cast reaches the clinic within 3 days.
Which 3D-printed orthoses does Gero3D offer today?
Upper-limb devices: personalized casts designed from each patient's scan (Short Arm, Thumb Spica and De Quervain casts), and the ONE Splint, a ready-made 3D-printed wrist splint in three sizes for the first visit.
Does Gero3D make 3D-printed AFOs?
Not yet. A 3D-printed orthotics and prosthetics (O&P) service, including ankle-foot orthoses, is in development. Our evidence review summarizes what published research shows about 3D-printed AFOs.
Who decides whether a 3D-printed orthosis is right for a patient?
Always the treating doctor or orthotist. Gero3D provides the scanning, design and production; treatment decisions stay with the clinician.
For clinics
Bring custom 3D-printed casts to your clinic
Free pilot for clinics: 10 casts at no cost, free training and equipment on us.