SLS 3D printer helps shop speed the production of foot orthoses

An SLS 3D printer has allowed Advanced Family & Sports Podiatry to shorten the time needed to ship a custom brace from two weeks to 24 hours. Images: AFSP

An Australian company that specializes in manufacturing custom foot, ankle, and other lower-limb braces has acquired a selective laser sintering-style 3D printer to help shorten delivery times. Advanced Family & Sports Podiatry’s new Sintratec S2 modular SLS system reportedly has cut delivery of some orthoses by nearly two weeks.

The 15-year-old, 10-employee company began experimenting with additive manufacturing technologies in 2020. The shop initially tried fused filament fabrication (FFF)-style printers, said the shop’s owner, Mark Ireland, but soon reached the technology’s limitations.

“We quickly realized the [FFF] parts did not possess the mechanical strength we required from our products,” he said. “We also trialed SLA (stereolithography), but unfortunately with the same outcome.”

He sought an alternative. “Our parts need to have a high degree of accuracy and can involve complex shapes to contour and help the foot and ankle function,” Ireland explained. “They also need to have some flexibility without shattering and have a high heat-deflection temperature to preserve an orthotic’s shape under stress.” Low moisture absorption is important, too, because of the environment orthoses are commonly used in.

According to Ireland, the SLS process is one of the additive technologies that can meet these demands.

Advanced Family & Sports took delivery of the Sintratec S2 in April 2021. Soon after, the full potential of SLS technology became evident,” said Ireland. “The biggest advantages to us are the speed of production, accuracy of the build, and unrestricted design freedom to test and push new shapes for the benefit of our clients.”

The shop produces custom and semi-customized foot orthoses from PA12 nylon. It’s now able to ship a custom orthotic in less than 24 hours instead of the customary two weeks.