APOS Additive Manufacturing

Context & Aim

Atlantic Prosthetic Orthotic Service (APOS) is 100% Irish Owned and is the only independent prosthetic and orthotic Irish manufacturer. They manufacture:

  • Prosthetics which are external devices fitted to mimic the functionality of missing limbs
  • Orthotics which are external devices used to maintain/alter the position of a joint or body part


APOS has identified a need to pivot its manufacturing method from current workflow to a more agile virtual or digitised model and Additive Manufacturing has been identified as a solution that could bridge the gap between scanning, prototyping and production while retaining the ability to revise models.


There is a potential method to deal with data translation and integrate this with existing clinical knowledge. Additive Manufacturing has the potential to give the company a global competitive advantage.


State of the Art Review

  • Identify key Additive Manufacturing technology
  • Identify potential scan partners
  • Identify potential software solutions


AM Technology Integration

  • Define clinical technological need
  • Skills gap analysis
  • Trial software solution


Transtibial/Below Knee Prosthetic Prototype

  • Patient Scan First Pass
  • 3D Modelling and Clinical Adjustment
  • Draft design
  • Initial single prototype production


Project Gap Analysis and Feasibility Review


New Digital Workflow designed by IMR and leveraged to build a working prototype patient-specific transtibial prosthesis in close collaboration with clinicians from APOS. IMR has identified a potential pathway to save APOS both time and cost while also expanding its offering.


Decision made to fully explore and develop the application.

APOS Additive Manufacturing feasibility fitting


Design for Manufacturing