Soft orthotics: creating the perfect fit with a 3D scanner

Soft textile orthoses are used in the treatment of certain medical conditions. Making these custom devices by hand is difficult, time-consuming, and susceptible to human error. A research project has developed a digital platform designed to simplify the production of soft orthoses.

In this MEDICA-tradefair.com interview, Dr. Sibylle Schmied explains how the textile orthoses are fitted using a 3D scanning process and reveals the challenges of the development process.

Dr. Schmied, the DITF has created a digital platform to produce soft orthoses. What prompted this development?

Dr.-Ing. Sibylle Schmied: The platform is not a completed development but is still a research project at this point. We teamed up with an industry partner and have developed soft orthotic devices for children and adults with movement disorders such as cerebral palsy, spasticity, or scoliosis. The soft orthotic treatment uses compression, which means the devices must be custom fitted to accurately match the user. That means, the measurement must always be very precise and tailored. One can make a lot of errors when you take measurements by hand. Our goal was to avoid these inaccuracies and to develop a process that uses digital images to ensure accurate measurements.

What are the therapeutic benefits of soft orthoses for the aforementioned medical conditions?

Schmied: Cerebral palsy affects physical perception, among other things. The idea is to increase perception using compression. In the case of scoliosis, the aim is to straighten and keep the body upright via compressive force that is embedded into the orthosis.

Our project studied torso orthoses; arms included. However, the process is designed to also be applicable to the lower extremities.

Which measuring tools were used in the project?

Schmied: We researched various methods, including 3D handheld scanners and photo tools available in pattern development programs for orthoses. We discovered that the biggest obstacle with 3D scanners is that low-cost devices are often inadequate. Meanwhile, high-quality models deliver great scans but are unaffordable for smaller orthopedic device companies.

How does the soft orthotics manufacturing process work via the platform?

Schmied: As mentioned earlier, the process itself is not yet ready-to-use. But ideally, a patient would be scanned by an orthopedic device company, which then uses a digital pattern to custom make a precisely fitting soft textile orthosis.

We still have some problems with the implementation. For example, it is difficult to get a good scan for people with scoliosis because their bodies are curved. Some patients with cerebral palsy cannot stand, which means you can only scan them if they are sitting or lying down. However, when a person lies down, their body shape changes.

We studied the various positions patients can assume as part of the project but unfortunately could not yet find any satisfactory solutions. The bodies are often also too asymmetrical to use photo tools. Thanks to the software, the digital platform works well with ideal bodies, but things get significantly more difficult as it pertains to divergent body shapes.

Have you found a solution for this?

Schmied: The project has ended for the time being. We would have to team up with software companies to find the right solutions. They would have to create tools that allow us to better process scans or images, especially when it comes to scanning people with disabilities in different postures.

Are you planning to further develop the platform and perhaps create a commercial product in the future?

Schmied: We definitely plan to improve the platform. We continue to address body shapes that are difficult for orthotics to fit. Whether or not it makes sense to commercialize the product is difficult to say because soft orthotic devices are unique and special by nature. For now, patients still must visit our industry partner, who measures their bodies on site and custom makes the orthotic device. However, the idea is to decentralize the process and enable orthopedic supplies stores to take the respective measurements.