Context & Aim

Atlantic Prosthetic Orthotic Service (APOS) are 100% Irish Owned and are 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 have identified a need to pivot their 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 & Clinical Adjustment
  • Draft design
  • Initial single prototype production

Project Gap analysis & 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 have identified a potential pathway to save APOS both time and cost while also expanding offering.


Decision made to fully explore and develop the application.

APOSAM feasibility fitting


Colin Meade
Industrial Researcher in Additive Manufacturing


Design for Manufacturing