OTWorld presents the opportunities afforded by additive manufacture in orthopaedic technology

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There is currently hot debate about prototype orthoses and prostheses being made on the 3D printer. The new additive manufacturing processes do indeed enable complex three dimensional shapes to be created – but to what extent can this printing technology replace the individual fitting of a device and, consequently, the patient's treatment in the hands of the orthopaedic technologist? Here, even modern manufacturing techniques soon hit obstacles. OTWorld 2016 will be considering the potential and the limitations of this 3D technology from 3 to 6 May. Several symposia at the World Congress provide an overview of the current state of play when it comes to the choice of materials, the methods of manufacture and variations in design. Presentations at the leading world trade fair will fill in the details relating to the latest solutions in the field of 3D printing.

"Additive manufacture is one of the much-discussed topics in technical orthopaedics, " emphasises Michael Schäfer, Member of the Board of Management of the German Association of Orthopaedic Technology (Bundesinnungsverband für Orthopädie-Technik) and member of the Steering Committee for OTWorld 2016. "OTWorld presents and discusses the latest possibilities for 3D printing in everyday orthopaedic practice, as well as the feasibility of its use, " observes Schäfer. "The trade and professional visitors can get a balanced picture of how and whether this technology is set to impact the everyday life of the technician." Manufacture of prostheses and orthoses using 3D printing techniques is still very much in its infancy, but there are some exciting developments to be seen in various research projects. "The first products are already on the market. They include waterproof prostheses, designer protective wear, cosmetic bridging pieces and 3D printed orthoses, " says the Managing Director of POHLIG GmbH.

WORLD CONGRESS: POSSIBILITIES FOR 3D PRINTING
"Additive manufacture and virtual, three-dimensional computer design have occasioned a complete rethink in the design of mechanical aids in technical orthopaedics, as well as opening up new horizons, " explains Schäfer." Three-dimensional shapes and complex structures can be created, even for small production runs. The geometry of all sorts of component can be freely and flexibly achieved; forces that act on them can be simulated so that both structural strength and stability can be specifically targeted and improved." The symposium "Additive Manufacturing – new manufacturing techniques in orthopaedic technology?" (4 May 2016, 3:00 p.m.) will deal with additive production methods, which are suitable for use in orthopaedic technology.

3D printing offers a whole dimension of design freedom, stresses Schäfer. It permits of minimalistic designs for orthoses, as well as the technical implementation of design requirements, which would be difficult to meet with handmade items: "We have already managed to create orthoses with breathable sections and, indeed, in unusual colours and with stylish designs. Our younger patients in particular are delighted." The potential of the new printing technology in terms of surfaces for prostheses is, for example, one of the topics in the symposium on "Innovative Design Variations in Lower Limb Prosthetics" (5 May, 4:45 p.m.). "We have invited two designers from Canada to join us for this; McCauley Wanner and Ryan Palibroda from the Allele Design Studio, whose protectors transform prosthetic legs into fashion statements and who have approached the design of prostheses from the exciting point of view of the fashion designer, " announces Schäfer.

At all events, the choice of plastics and metals for 3D printing is still limited and has, therefore, set limits to its use in orthopaedic technology. Schäfer is convinced, however, that" OTWorld will provide new stimulus with regard to the variety of materials and designs." Accordingly, the symposium will provide information on "Innovative Materials and Manufacturing Techniques in Orthopaedic Technology" (6 May 3:00 p.m.) and will include, amongst other things, 3D printing. Furthermore, Dr. Urs Schneider, Head of the Department of Biomechatronic Systems at the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA), will devote his keynote speech entitled "Opportunities and challenges in the manufacture of the orthopaedic technology of tomorrow" to the question of how 3D printing will change the way orthoses and prostheses are made to meet the individual patients needs (4 May, 2:00 p.m.).

LEADING WORLD TRADE SHOW: FABBUS WITH STATE-OF-THE-ART 3D PRINTING TECHNOLOGY
At the worlds leading trade show of its kind, you can experience additive manufacturing live: the FabBus "Wolfgang" from the Goethe Lab project for additive manufacturing at the university of applied sciences in Aachen has demonstrations of modern 3D printing technology on two floors. This mobile laboratory of the future is installed in an adapted double-decker bus, which was once part of the Berlin traffic network.

"We demonstrate a variety of printing technologies, using eleven models of 3D printer, so that our specialist visitors can get an overview of the usefulness of this technique in orthopaedic technology, " explains Professor Dr.-Ing. Andreas Gebhardt, Dean of the Faculty of Mechanical Engineering and Mechatronics at the Aachen University of Applied Sciences." Also presented in demonstrations and lectures are the future opportunities for orthopaedic technology that are to be found in additive manufacturing processes – and where the limits are." Eight work stations, at which 3D objects can be designed in virtual format, are built into this unique classroom. In the showroom, 3D printers can be seen in action, together with the resultant print outs. The FabBus will stop off in Hall 1, Stand A54, – close to the Campus.

"We have brought along a 3D-printed prosthetic hand as our showpiece, " says Gebhardt. The Ama Prosthesis – Additive Manufactured Prosthesis – is a prototype that has been developed in the Faculty of Mechanical Engineering and Mechatronics. It is a body-powered prosthesis, which might, for instance, be used as a form of treatment for instance, in the third world. As a prosthesis which can "grow with you" it is thought to be specifically suited to children. "Elements of the prosthetic hand are produced in the FabBus. We have, moreover, brought some partially assembled prosthesis with us, as well as the entire model in all its complexity, " explains Gebhardt. The University of Applied Sciences in Aachen will be presenting itself and its work on the joint stand Campus, next to the FabBus.

CAMPUS: MOBILE PRODUCTION SYSTEM
Campus is a joint stand on which universities, colleges, research institutions and start-up companies showcase their innovations. Thus, the Fraunhofer Institute for Manufacturing Engineering and Automation IPA will, together with CassaMobile, be presenting a flexible, modular production system on wheels. The 3D-printed product – an orthosis for instance – is produced in a 20 ISO container exactly where it is needed. Eleven partners from 6 European countries are working on this joint EU sponsored project.

And last, but certainly not least, several companies at OTWorld have announced new solutions in the world of 3D printing – including Gottinger Handelshaus, stamos + braun prothesenwerk, TechMed 3D, Ottobock-Partner UNYQ Design and Vorum.

OTWorld is a unique combination of Trade Show and World Congress. Every two years the event offers a wide variety of choice among current trends, growth strategies and product innovations for certified prosthetists and orthotists, physiotherapists, doctors, orthopaedic shoemakers, podiatrists, as well as engineers and funding organisations. In 2014, OTWorld attracted 20,400 visitors from over 80 countries, together with 548 exhibitors from 37 nations. Notional sponsor of OTWorld is the German Association of Orthopaedic Technology (Bundesinnungsverband für Orthopädie.Technik). Owners of the OTWorld trademark and organisers of the World Congress are Confairmed GmbH. Leipziger Messe GmbH are responsible for the Trade Show.

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