3D Scanners in Medical Technology & Prosthetics
TitleDigital revolution: How 3D scanners are changing medical technology
3D scanners are revolutionizing medical technology and prosthetics. The advancing digitalization through 3D scanners is bringing about a huge change. From the manufacture of prostheses and orthoses to the customization of medical aids, the technology is revolutionizing both precision and efficiency.
The use of non-contact 3D scanners makes it possible to precisely capture body structures and design individual solutions that are optimally tailored to the patient. Find out how modern 3D technology optimizes patient care.
Title Perfect fit thanks to 3D scanning - Modern prosthetics & orthopaedic technology
In traditional orthopaedic technology, the production of prostheses and orthoses was often a lengthy and laborious process that relied on plaster casts, manual measurements and precision craftsmanship.
The use of 3D scanners has fundamentally changed this. Instead of laborious physical impressions, modern scanners capture the shape of the body digitally and in impressively high resolution.
The result is faster, more precise and more individualized production, which makes it possible to create exact models of the body parts concerned and to process this data efficiently.
TitleHow is 3D scanning changing orthopaedic technology?
The implementation of 3D scanners is profoundly changing orthopaedic technology:
Non-contact measurement: 3D scanning technology enables non-invasive measurement of the body, increasing patient comfort and minimizing the risk of errors.
Faster production & higher precision: Less reworking is required thanks to fast acquisition and high-precision data. Sources of error and deviations are minimized as the scanners work with a very high level of detail.
Customized solutions & increased comfort: Patient-specific measurements can be captured accurately and without contact. They can be integrated directly into the digital workflow, ensuring a custom-fit and individually adapted fitting. This significantly increases the comfort and functionality of the aids.
Cost savings & material efficiency: Digital models and virtual adjustments reduce material consumption and working time, helping to cut costs, which is beneficial for both patients and providers.
TitleHow are 3D scanners used in medical technology?
Prostheses
Custom-made leg, arm and hand prostheses are created using precise 3D scans that are tailored to the patient's individual needs and anatomy.
Orthoses
Precise body measurements are essential for the production of joint orthoses, back orthoses or hand orthoses. 3D scanners ensure a high degree of accuracy of fit.
Customized medical products
3D scanners enable the rapid production of patient-specific products that significantly increase patients' comfort and quality of life.
Title3D scanning in prosthetics: Scanner technologies & application
Various scanner technologies are available for the production of prostheses and orthoses, each of which is specialized for different requirements:
- LiDAR scanners: Rely on lasers and are ideal for large areas of the body such as the back, as they provide precise depth information.
- White light scanners: Work with structured light and are particularly suitable for detailed scans of smaller areas of the body, such as hands and feet.
- Infrared scanners: This technology enables fast and precise capture and is suitable for capturing soft surfaces and slight movements.
- Hybrid scanners: Combine multiple technologies to offer high flexibility and depth of detail, making them ideal for a wide range of body areas.
TitleFrom 3D scan to prosthesis as 3D print
Creating a prosthesis or orthosis with a 3D scanner involves several precise steps:
Scanning the body part
Different scanner technologies are used depending on the level of detail required and the area of application. For example, a white light or infrared scanner could be used for a lower leg prosthesis, while a LiDAR scanner is ideal for detailed back or full-body scans. Hybrid scanners combine the strengths of different technologies and precisely capture both contours and deep structures.
Data processing
The scanned data is loaded into special software that enables the model to be digitally processed. At this stage, orthopaedic technicians can make adjustments to perfectly adapt the prosthesis or orthosis to the patient's anatomy.
Modeling & fabrication
The processed scan data is used for production. 3D printing is increasingly being used for this, as it enables cost-effective and detailed production. Particularly in the field of orthopaedics, 3D printing enables the fast and precise production of customized aids.
Fitting & fine-tuning
Finally, the finished aid is tested on the patient and, if necessary, slightly adjusted to ensure optimum fit and functionality.
TitleOther methods for manufacturing prostheses
In addition to 3D printing, there are other established manufacturing processes that are based on data previously captured with a 3D scanner. These processes often allow an even wider choice of materials and offer additional advantages, depending on the functional requirements and the desired wearing comfort of the prosthesis.
Here are some of the common alternatives:
- CNC milling
Application: CNC milling is a widely used process for manufacturing prosthetic components, especially for stable materials such as metal or high-strength plastics.
Procedure: The data from the laser scan is imported into a CAD program and converted into milling data. The CNC machine then produces the prosthetic component by precisely removing material.
Advantages: CNC milling offers very high precision and material stability, which is particularly necessary for durable and resilient prostheses.
- Casting & molding
Application: Casting is particularly suitable for parts that need to have an organic shape and high flexibility, such as liners or soft inserts in prostheses.
Procedure: The scanned data is used to produce a casting model, which is then used to make the mold. This mold is then filled with materials such as silicone or polyurethane to produce the final prosthesis.
Advantages: Ideal for soft and flexible prosthetic parts that need to have close, comfortable skin contact.
- Forging & casting for metal parts
Application: For specific prosthetic components such as joints or mechanical connections that have to withstand high loads, metal parts are often required that are produced by forging or casting.
Procedure: The laser scan data is converted into models or molds for casting or forging. These parts are then cast or forged in a metal alloy and further processed.
Advantages: Enables very resilient prosthetic parts that can withstand daily wear and tear for a long time.
- Injection molding
Application: This process is often used to produce large quantities of prosthetic parts in a standardized form, but is also suitable for individual adaptations.
Procedure: A laser scan provides the data for a mold or a negative impression, which then serves as the basis for the injection mold. In a subsequent step, the prosthesis part is molded from plastic or other suitable materials.
Advantages: The injection molding process is suitable for the rapid production of components in series, is cost-efficient and allows a precise surface design.
- Lamination
Application: Laminated prosthetic sockets are frequently used in orthopaedic technology, especially for leg prostheses.
Procedure: A negative mold of the body part is created based on the scan data. This mold is then laminated with various layers of carbon fiber, glass fiber or other materials and then hardened.
Advantages: This process offers high stability and lightness at the same time. Lamination makes it possible to produce particularly strong and durable prosthetic sockets.
- Stereolithography (SLA)
Application: Although stereolithography technically belongs to the field of 3D printing, it is a separate process with special properties. It is often used for very detailed prosthetic parts.
Procedure: The scanned model is created in thin layers by a special resin that is cured layer by layer with UV light.
Advantages: SLA offers an exceptionally high resolution and surface quality, which is particularly ideal for denture parts with the finest details.
3D scan data can therefore be further processed in various methods to produce prostheses. The choice of manufacturing process depends on the specific requirements of the prosthesis - such as stability, flexibility, material properties and costs. Each of these processes benefits from the precise and individual data of a laser scan, which serves as the basis for customized, comfortable and high-performance prostheses.
TitleHow does the workflow change?
Digitization largely eliminates the need to make plaster casts manually.
The 3D scan data allows adjustments to be made digitally and offers the option of simulating adjustment processes on screen. This saves resources and minimizes sources of error, as making and fitting on the computer allows a very high level of precision.
Thanks to its efficiency and accuracy, the new workflow is an immense asset for orthopaedic technicians and patients alike.
TitleOur recommendations for 3D scanners
ARTEC
Artec 3D scanners are special because they offer exceptionally high accuracy and ease of use and have been specially developed for the precise capture of complex surfaces.With advanced technologies such as structured light and powerful algorithms, Artec scanners capture even the finest details and texture-rich surfaces in high resolution and realistic colors. They are lightweight, portable and require no markers, making them ideal for medical, industrial and creative applications. The intuitive software allows for seamless editing and adjustment of scan data, greatly simplifying and optimizing the workflow.
Advantages:
- Powerful software
- Good support
- High accuracy = 0.1mm
- Combines multiple scans
SHINING3D
Shining3D scanners are highly valued in the medical field for their precision, versatility and user-friendly design. They utilize innovative technologies such as hybrid light sources (laser and LED) and offer flexible scanning modes suitable for a wide range of applications - from detailed body and facial scans to capturing intricate anatomical structures. These scanners make it possible to create patient-specific models quickly and accurately and to seamlessly integrate the scan data into digital workflows, which significantly improves the fitting and production of medical devices such as prostheses or orthoses.
Advantages:
- Powerful software
- High accuracy = 0.1mm
- Smoothing possible within the software
- Fair price
TitleLooking to the future: Which developments do we expect?
The combination of 3D scanning and 3D printing has enormous potential for orthopaedics and medical technology.
Scanners are expected to become even more compact, user-friendly and accurate in the future.
In addition, the integration of artificial intelligence could further optimize the process by using intelligent algorithms to provide suggestions for optimal fitting and material usage.
Are you interested in working with laser scanners? We will be happy to advise you.
