New technologies

3D printing in orthotics: braces, helmets and custom-made solutions

3D scanning, digital design and 3D printing for orthoses that are thinner, lighter and made exactly to fit you, from paediatric braces to plagiocephaly helmets.

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Little girl wearing 3D-printed paediatric AFO braces

3D printing has changed the way many orthopaedic products are made. Instead of heavy materials and many manual stages, the body is scanned digitally, the orthosis is designed on a computer and then printed with precision. At Hlamidis Orthopaedic Center in Thessaloniki we use 3D scanning and an HP 3D printer to make custom-made solutions, mainly for children, but also for athletes and prosthesis users.

How it works: from scan to finished orthosis

Assessment: we look at your needs and, in consultation with your doctor, choose the right type.
Measurements: we take a 3D scan of the foot, head or face, or a cast where needed.
Design: using specialist software, we design the orthosis on your digital model.
Printing: the 3D printer produces the orthosis with thin walls and ventilation structures.
Fitting, handover and check-ups: we test the fit, make the final adjustments and schedule follow-up checks.

What we make with 3D printing

Paediatric AFO and SMO braces

For children with cerebral palsy and similar conditions, 3D-printed paediatric AFO/SMO braces help improve mobility and ankle control. They are thin and light, fit more easily into shoes and come in five basic types (Active, Dynamic, Control, Block, Rehab), each adapted to the individual child.

Plagiocephaly helmet

The Talee paediatric helmet is an orthotic treatment for plagiocephaly, brachycephaly and dolichocephaly in babies. Its perforated structure allows ventilation, while the slim design makes it comfortable for the baby. After handover, scheduled check-ups follow so that we can monitor progress.

Protective face masks

After a fractured nose or cheekbone, a protective mask designed on a scan of your face lets you return to your sport without restricting your field of vision.

8Sole insoles

8Sole insoles are designed on the basis of your diagnosis and a 3D scan of your foot, and are printed with corrective features made just for you, for everyday wear, sport or children.

UNYQ prosthetic covers

UNYQ covers are 3D-printed covers for below-knee and above-knee prostheses, available in many designs and colours, that turn your prosthesis into an expression of your personal style.

Who it is for

3D printing is particularly useful when an orthosis needs to be very light, well ventilated and fit precisely on a body that changes quickly, as is the case with babies and children. We also recommend it to athletes who need protection without losing movement, and to prosthesis users who want custom-made insoles or covers. The choice of method is always based on the condition, not on the technology.

Why 3D printing

Precision: digital scanning captures the shape of the body in detail.
Less weight and bulk: orthoses can be thinner and lighter than conventional ones.
Ventilation: perforated structures reduce sweating, which is especially important for babies and children.
Appearance: designs and colours that make children want to wear their brace.

You will find more about 3D printing in prosthetics and orthotics, as well as on our 3D-printed paediatric braces page.

3D printing and EOPYY

Cover by EOPYY (ΕΟΠΥΥ), Greece’s national health insurance organisation, applies to people insured in Greece and depends on the type of product and the diagnosis. For some products, such as plagiocephaly helmets, there is no specific category in the price list. Contact us so that we can check what applies in your case, or see our page on EOPYY and reimbursement. If you are not insured in Greece, EOPYY reimbursement does not apply; you can pay privately, and any cover depends on your own insurer’s rules – contact us and we will give you the information you need for your case.

Paediatric solutions with 3D printing

Smiling little girl standing on the grass wearing white 3D-printed paediatric AFO braces inside her shoes

3D-printed paediatric AFO and SMO braces

Thin, lightweight ankle-foot braces for children, designed from a 3D scan and printed on a 3D printer, so that your child can feel the difference with every step.

Mother hugging her sleeping baby, who is wearing a pink perforated 3D-printed plagiocephaly helmet

3D-printed helmet for plagiocephaly and brachycephaly (TaLee)

TaLee is a 3D-printed cranial remoulding helmet for babies. It is light, thin and perforated, so that your baby can wear it comfortably throughout treatment.

FAQ

Frequently asked questions

Can’t find your answer? Our prosthetists are happy to help.

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Are 3D-printed braces durable?

Yes. 3D-printed braces are designed for everyday use by very active children. The software allows us to reinforce the areas that take the greatest forces and to make the rest thinner. Like any paediatric brace, they need regular check-ups and replacement as your child grows.

Does 3D scanning hurt?

No. Scanning is done with a handheld scanner that captures the shape of the body without pressure and without any contact with plaster, and it takes just a few minutes. That is why it is especially suitable for babies and young children, who find it hard to stay still while a plaster cast is taken.

How long does it take to make a 3D-printed orthosis?

It depends on the product. For paediatric braces and helmets, once the device has been made we book a fitting appointment and, if the fit is right, handover takes place the same day. Protective masks are usually delivered within a few days of the scan. We will give you an exact timeline after the assessment.

Does EOPYY cover 3D-printed orthoses?

For people insured in Greece, cover depends on the type of orthosis and the diagnosis stated on the doctor’s prescription, not on the manufacturing method. For some products, such as the plagiocephaly helmet, there is no specific category in the EOPYY price list. Contact us so that we can check what applies in your case.