3D Printed Prosthetics & Orthotics Design Course

Lesson 1 • Biomechanics of Human Movement

Introduces gait analysis, joint kinematics, and force distribution principles. Connects movement science to functional device requirements throughout the course.

Lesson 2 • Classification of Orthotic Devices

Surveys spinal, upper-limb, and lower-limb orthosis categories and their clinical indications. Distinguishes orthotic from prosthetic design goals.

Lesson 3 • Anatomy and Physiology for Device Design

Covers skeletal, muscular, and soft-tissue structures relevant to limb loss and deformity. Provides the anatomical foundation required for all subsequent device design decisions.

Lesson 4 • Patient Assessment and Clinical Workflow

Outlines the clinical intake process, functional goal-setting, and interdisciplinary team roles. Grounds design decisions in patient-centred outcomes.

Lesson 1 • Hardware, Printers, and Workflow Setup

Guides setup of desktop and industrial printers, slicer software, and file preparation pipelines. Prepares students to manage a functional clinical print lab.

Lesson 2 • Material Testing and Failure Analysis

Introduces mechanical testing methods and failure mode identification for printed components. Ensures students can validate device safety before patient fitting.

Lesson 3 • Print Parameters and Quality Control

Covers layer height, infill density, print orientation, and support strategies for structural integrity. Directly impacts device strength and surface finish.

Lesson 4 • Polymers for Prosthetics and Orthotics

Examines PLA, PETG, TPU, nylon, and carbon-fibre composites for structural and flexible components. Links material properties to device performance requirements.

Lesson 1 • Patient Preparation and Scan Protocols

Covers positioning, skin marking, and scan environment setup to minimise artifacts. Proper protocols directly determine downstream model accuracy.

Lesson 2 • Anatomical Landmark Extraction

Extracts bony landmarks, circumferential measurements, and volume data from scan meshes. Provides quantitative inputs for socket and shell design.

Lesson 3 • Scanning Technology Fundamentals

Compares structured-light, laser, and photogrammetry scanning methods by accuracy and clinical suitability. Establishes selection criteria for different body regions.

Lesson 4 • Point Cloud and Mesh Processing

Teaches noise reduction, hole filling, and mesh decimation using professional scan software. Produces watertight meshes suitable for CAD import.

Lesson 1 • Introduction to CAD Software for P&O

Surveys dedicated P&O CAD platforms and general-purpose tools, comparing workflows and feature sets. Orients students to the software environment used throughout the chapter.

Lesson 2 • Socket Geometry and Fit Principles

Translates clinical fit concepts—relief areas, load-bearing zones, and trim lines—into CAD geometry. Bridges clinical knowledge from Chapter 1 with digital modelling.

Lesson 3 • Parametric Socket Modelling Workflow

Guides students through a step-by-step parametric workflow from scan import to finished socket shell. Establishes a repeatable, efficient design process.

Lesson 4 • Freeform Sculpting and Local Modifications

Uses push-pull sculpting tools to refine pressure relief areas and custom contours. Enables fine-tuned adjustments that parametric tools cannot achieve alone.

Lesson 1 • Spinal Orthosis and TLSO Design

Covers trunk scan processing, panel design, and opening/closure system integration for spinal orthoses. Extends orthotic CAD skills to the axial skeleton.

Lesson 2 • Orthotic Design Principles in CAD

Applies biomechanical force control concepts to orthotic shell geometry and stiffness distribution. Connects Chapter 2 biomechanics to digital orthotic design.

Lesson 3 • Knee and Hip Orthosis Modelling

Addresses multi-segment orthosis design, hinge placement, and joint axis alignment in CAD. Builds complexity beyond single-segment AFO design.

Lesson 4 • Ankle-Foot Orthosis Design Workflow

Walks through a complete AFO design from scan import to print-ready model. Serves as the primary applied workflow for lower-limb orthotic design.

Lesson 1 • Topology Optimisation Techniques

Uses topology optimisation to redistribute material for maximum stiffness at minimum weight. Directly reduces device mass while maintaining structural integrity.

Lesson 2 • Finite Element Analysis Fundamentals

Introduces FEA concepts—mesh generation, boundary conditions, and load application—in the context of prosthetic and orthotic devices. Provides the analytical foundation for design validation.

Lesson 3 • Iterative Design and Simulation Workflow

Establishes a design-simulate-refine loop integrating CAD, FEA, and print validation. Produces a documented design history demonstrating performance improvement.

Lesson 4 • Load Case Definition for P&O Devices

Defines realistic loading scenarios for gait, stair climbing, and fall events based on body weight and activity level. Ensures simulations reflect actual patient use conditions.

Lesson 1 • Static and Dynamic Alignment

Performs bench alignment and dynamic alignment adjustments based on observational gait analysis. Directly improves device function and patient safety.

Lesson 2 • Functional Outcome Measurement

Applies standardised outcome measures—timed walk tests, balance scales, and patient-reported tools—to quantify device performance. Provides objective data for clinical decision-making.

Lesson 3 • Pre-Fitting Inspection and Preparation

Covers post-print inspection, edge finishing, padding application, and hardware assembly before patient contact. Ensures device safety and comfort at first fitting.

Lesson 4 • Initial Fitting and Donning Procedures

Guides the first patient fitting session, including donning technique, initial weight-bearing, and pressure mapping. Identifies fit issues requiring immediate modification.

Lesson 1 • Quality Management System Essentials

Introduces quality management system principles—document control, corrective action, and management review—applicable to P&O practices. Provides the operational framework for compliant production.

Lesson 2 • Biocompatibility and Material Compliance

Addresses biocompatibility testing standards, material traceability, and supplier qualification for skin-contact printed materials. Ensures material safety for patient use.

Lesson 3 • Clinical Documentation and Reimbursement

Covers prescription documentation, clinical justification, and coding principles required for device reimbursement. Connects clinical and regulatory workflows to practice sustainability.

Lesson 4 • Medical Device Regulatory Frameworks

Surveys global medical device classification systems, conformity assessment pathways, and manufacturer obligations. Establishes the regulatory context for all device design decisions.