3D scanning is changing how orthotics and prosthetics are made. It replaces manual methods with faster, more accurate, and non-invasive digital workflows. This technology ensures better patient care, reduces material waste, and speeds up production.
Key Benefits of 3D Scanning:
- Faster Measurements: Scanning takes 3-6 minutes compared to 30+ minutes for manual casting.
- Accuracy: Submillimeter precision (99-100% accuracy).
- Patient Comfort: Non-invasive and ideal for sensitive conditions.
- Customization: Tailored designs for unique anatomies.
- Efficiency: 60% fewer follow-up visits and faster device fittings.
Manual vs. 3D Scanning: Quick Comparison
| Aspect | Manual Casting | 3D Scanning |
|---|---|---|
| Time Required | 30+ minutes | 3-6 minutes |
| Material Waste | High | 90% less |
| Data Storage | Physical space | Digital storage |
| Ease of Changes | New cast required | Instant digital updates |
3D scanning improves both patient outcomes and provider workflows, making it an essential tool in modern healthcare.
How 3D Technology is Revolutionizing Orthosis Manufacturing
Manual vs. Digital Methods
Switching from manual casting to 3D scanning has changed the way orthotics and prosthetics are designed. This shift affects both practitioners and patients by improving accuracy, saving time, and enhancing the overall process.
Comparing Measurement Methods
Manual casting depends on the skill and experience of the practitioner, which can sometimes lead to inconsistent results. On the other hand, 3D scanning provides consistent and precise measurements every time.
| Aspect | Manual Casting | 3D Scanning |
|---|---|---|
| Time Required | 30+ minutes | 3-6 minutes [3] |
| Material Waste | High | 90% less [3] |
| Data Storage | Physical space needed | Digital storage |
| Modification Ease | New cast required | Instant digital changes |
These advancements bring several benefits:
- Say goodbye to the mess and discomfort of plaster casting.
- Patients with mobility challenges find the process much easier with 3D scanning.
These improvements are at the core of Sidekick Interactive’s tailored solutions.
Sidekick Interactive Projects
For over a decade, Sidekick Interactive has been creating tools that help bridge the gap between manual methods and modern digital workflows. Their solutions target the challenges of transitioning from traditional processes to digital ones, particularly in terms of accuracy and efficiency.
3D Scanning Process Steps
Modern 3D scanning combines accuracy and efficiency through a well-organized process:
Patient Scanning
The process starts with handheld or tablet-based 3D scanners that digitally capture the patient’s anatomy. This non-invasive method records the shape, size, and contours of the affected limb or body part with submillimeter precision. These devices achieve an impressive accuracy rate of 99-100% compared to traditional manual techniques [5]. This high level of consistency ensures dependable results, regardless of the practitioner or facility.
Data Processing
Once the scan is complete, specialized CAD software converts the raw data into detailed device designs. Tools like Sidekick’s medical apps streamline this step, which typically includes:
| Processing Step | Purpose | Outcome |
|---|---|---|
| Scan Optimization | Removes unwanted digital noise | Clean and accurate 3D model |
| Pressure Mapping | Examines weight distribution | Improved comfort areas |
| Design Refinement | Adjusts for patient-specific needs | Tailored fit and function |
Prosthetists use tools like pressure mapping and biomechanical analysis to fine-tune designs [2][3]. Advanced systems can even suggest design adjustments based on anatomical and movement data [5].
Manufacturing and Fitting
3D printing brings these digital designs to life, using lightweight yet strong materials. Technologies like Multi Jet Fusion (MJF) ensure the final product matches the digital model with a precision of up to 0.3mm [5].
The fitting process includes several steps to ensure the device meets the patient’s needs:
- Initial alignment and comfort assessment
- On-site adjustments, such as heat molding or adding padding
- Functional testing during activities to evaluate performance
- Incorporating patient feedback for final modifications
This seamless workflow not only improves comfort but also enhances overall clinical outcomes. Sidekick’s decade of experience in merging clinical expertise with cutting-edge technology is evident in this end-to-end process.
Results for Users and Providers
Patient Benefits
Thanks to improved manufacturing processes, patients see better comfort and outcomes, especially in complex cases like partial foot amputations [3]. Scanners can detect even the smallest anatomical details, allowing for custom-fit devices that enhance weight distribution and minimize pressure points [6].
Some key improvements for patients include:
- Fittings that are 50-75% faster [3]
- 60% fewer follow-up visits required [3]
- Customized solutions tailored for unique anatomies [3]
Provider Advantages
These advancements not only benefit patients but also make life easier for providers by accelerating design workflows by 40-60%, as highlighted in the Data Processing section.
Time and Resource Efficiency
- Design times drop from hours to just minutes, thanks to Sidekick’s proven tools [7].
- Remote specialists can now collaborate more easily [3].
Improved Clinical Outcomes
- Digital measurements align almost perfectly with manual ones [5].
- Providers can track patient progress digitally, monitoring anatomical changes over time [3].
- Adjustments to digital models are simple and don’t require starting over with new scans [2].
Sidekick’s integration with electronic health records (EHR) systems ensures smooth data storage and supports collaborative care [5]. Providers also report cutting costs through reduced material waste [5] and fewer device remakes, thanks to the higher accuracy of initial designs [2]. These efficiencies highlight Sidekick’s commitment to refining clinical workflows while maintaining precision and reliability.
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Sidekick Interactive Experience
Sidekick has spent over a decade developing clinical-grade mobile solutions that streamline orthotic workflows with specialized medical apps.
Medical App Development
Sidekick’s medical apps are designed to blend clinical accuracy with ease of use. Key features include:
- Millimeter-accurate scanning using smartphones
- Real-time 3D model generation
- Integration with CAD software and cloud-based collaboration tools [1][5]
These tools have contributed to a 60% reduction in follow-up visits for patients.
Industry Partnerships
Collaborations with industry leaders have delivered measurable benefits:
- 30% faster prosthetic fittings through partnerships with manufacturers [9]
- 25% fewer follow-up visits for pediatric orthotics, thanks to growth-prediction algorithms [4]
- Higher acceptance rates for pediatric orthotics, driven by AI-assisted designs [10]
Data Security Standards
Sidekick prioritizes data security and compliance by implementing robust measures:
| Security Measure | Details |
|---|---|
| Data Protection | End-to-end encryption |
| Compliance | Adheres to HIPAA and GDPR |
| Access Control | Multi-factor authentication |
| Data Storage | Secure cloud backups |
| Staff Training | Regular education on protocols [7] |
New Technology Developments
Sidekick, with over a decade of experience in medical app development, is now incorporating advanced tools like AI and motion analysis into its offerings.
AI Applications
By analyzing historical scans, AI can now predict anatomical changes, allowing for timely adjustments. For example, the Rheo Knee XC, developed by Sidekick in partnership with Össur in 2023, uses machine learning to reduce stumbles by 35% [6]. These algorithms consider variables such as changes in residual limb volume and activity levels.
Movement Analysis
Sidekick’s systems integrate pressure mapping sensors with anatomical scans to evaluate patients’ gait, range of motion, and biomechanics [3]. This technology provides:
- Real-time gait analysis during everyday activities
- Identification of pressure points to improve comfort
- Personalized movement recommendations based on unique patterns
These hardware features are complemented by updates to patient-facing software tools.
Mobile App Updates
- Adjustments for activity-specific stiffness through a smartphone [4]
- Tracking usage patterns with embedded sensors
- Remote consultations supported by real-time data sharing
Conclusion
Industry Impact
3D scanning has reshaped how orthotics and prosthetics are produced, delivering a 30% improvement in fitting accuracy while significantly reducing traditional workflow times [6][3]. Sidekick, with a decade of experience in clinical workflows, has played a key role in this shift. Providers have reported measurable improvements in both production efficiency and patient outcomes.
"Once the workflow was in place, the benefits were worth the investment, providing consistency and quality in their prosthetic production." – Bionic Prosthetics Team, 2023 [8]
Working with Partners
Sidekick’s projects highlight that successful technology partnerships depend on several key factors. Based on over 100 clinical implementations, these partnerships often share common traits:
| Selection Criteria | Key Considerations |
|---|---|
| Technical Expertise | Proven success in medical applications |
| Data Security | Strong data protection protocols |
| Integration Capabilities | Smooth alignment with clinical workflows |
Healthcare providers should prioritize partners skilled in managing medical data and integrating with clinical workflows. Experience has shown that partners offering thorough training often lead to better long-term results.
To ensure success, focus on partners who can scale their solutions without compromising on quality.
FAQs
How is a 3D scanner used in healthcare?
3D scanning plays a crucial role in improving orthotic and prosthetic care, as seen in Sidekick’s clinical applications. It focuses on three main areas:
Main Uses:
- Prosthetic sockets: Enables digital limb scanning for same-day modeling.
- Custom orthotics: Provides detailed anatomical scans to create insoles tailored to patient needs.
This technology delivers precise measurements comparable to traditional methods, making it easier and faster to design custom medical devices.
| Application | Benefits | Workflow Time |
|---|---|---|
| Prosthetic Sockets | Accurate digital limb scanning | Same-day scanning/modeling |
| Custom Orthotics | Precise anatomical mapping for insoles | Same-day scanning/modeling |
Clinics using Sidekick’s solutions benefit from:
- Better customization with patient-specific designs.
- Long-term tracking of anatomical changes for adaptive devices.
- Smoother transitions from temporary to permanent devices.
With Sidekick’s 3D scanning tools, patients receive better-fitting devices that adjust to their evolving needs, leading to improved care and comfort.
