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.

Challenge

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.

Solution

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

Results

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.

Impact

Decision made to fully explore and develop the application.