Episode #99 | 3D Printing for Orthotics & Prosthetics (Virtual Event)

The Lattice (Official 3DHEALS Podcast)

Orthotics and prosthetics are entering a new era. Instead of hand-built devices that take days to shape and adjust, clinicians can now scan a limb, tune the geometry in software, and print a device that fits with impressive consistency. This episode explores how that shift is happening in real clinics and fabrication labs by hearing from experts who are shaping the future of digital O and P.

We have Michael Schmitt of Prosthetic Plus , who has moved from traditional clinical practice into advanced additive manufacturing and now helps run a central fabrication site that blends MJF and FDM production. He explains how accurate scanning and thoughtful CAD design create devices that can be reprinted months later from the same file in a perfect new size. David Johnson of HP builds on this by showing how polymer Multi Jet Fusion has become a reliable platform for orthotics and prosthetics, offering durable materials, isotropic strength, and the throughput needed for large-scale production.

Once the prints come off the build plate, Emilie Simpson of DyeMansion
explains how they are transformed into smooth, hygienic, biocompatible devices through cleaning, surfacing, vapor smoothing, and deep-dye coloring. Her work shows why post-processing is essential for patient comfort and clinical durability. Finally, Tara Wright of Gillette Children’s Specialty Healthcare brings everything back to the patient. She shares a compelling case where her team scanned and printed a replacement UCBL that matched the feel of a worn original, cut fitting time dramatically, and performed well for more than fifteen months. Her experience demonstrates how digital production can raise consistency and reduce strain on clinicians.

Together, these voices map out a practical path for clinics that want to adopt scan-to-print workflows. Start with accessible FDM printers to learn digital modification. Move to production with MJF through central fabrication or service bureaus. Scale when your volume, staffing, and materials align, and explore decentralized scanning with centralized manufacturing to broaden access.

Whether you are a clinician, technician, engineer, or healthcare innovator, this conversation offers a clear look at how digital manufacturing is transforming O and P. Tune in to learn how these tools can deliver better fit, faster turnaround, and more equitable access for patients everywhere.

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1. Welcome & 3DHEALS Mission (00:00:00)

2. Introduction (00:02:39)

3. Michael’s Path From Handcraft To Digital (00:02:43)

4. Garage Printers To Central Fabrication (00:05:37)

5. Moving From FDM To HP Powder Bed (00:12:05)

6. Lattices, Liners, And Patient Comfort (00:15:35)

7. Partial Feet, TPU, And Hybrids (00:18:30)

8. Custom Gauntlets And Printed Straps (00:22:40)

9. Upper Limb Devices And DIP Fingers (00:27:10)

10. Reprints, Repeatability, And Scaling (00:31:20)

11. Q&A: Tools, Software, And Materials (00:33:01)

12. HP Workflow: Scan To Print (00:39:43)

13. Nesting, Materials, And Throughput (00:44:20)

14. Process Control And Build Strategy (00:48:40)

15. Post-Processing Deep Dive (00:54:21)

16. Biocompatibility, Smoothing, And Dye (00:58:40)

17. Durability, Hygiene, And Colorfastness (01:04:00)

18. Introducing Gillette Children’s Use Case (01:07:30)

19. Scanners, Carvers, And Partnerships (01:11:10)

20. Research On 3D Printed AFOs (01:15:05)

21. Case Study: Copying Legacy UCBLs (01:18:15)

22. Service Bureaus And Hybrid Workflows (01:23:05)

23. Regulatory Realities For Cranial Helmets (01:26:20)

24. Scalability, Economics, And Adoption (01:31:40)

25. Global Access And Decentralized Models (01:38:05)

26. Wishes, Next Steps, And Closing (01:42:45)