In addition to experienced disability services, 3D physio offers 3D design, with CAD modeling, 3D printing, and other custom manufacturing to people in the disability and health sector. The applications are limited by imagination only. Sometimes people don’t know where to start, so some tangible case examples are listed here:
There are lots of other applications; Get in touch if you have a requirement or an idea that you would like to explore.
Especially in the disability field, unique participants often benefit from, or require an individualised solution. 3D printing and other new production processes are suited to producing one-off parts that are functional and cost effective. There are various people around town and on the internet that will design and produce parts this way but most of these 3D printing people are not experienced with disability or health; time and money can easily be misdirected. At 3D Physio, we have a rare combination of experience in health and disability equipment as well as expertise in 3D CAD modelling and a room full of 3D printers for rapid production of parts. 3D Physio is not a 3D printing service; we are an Assistive Technology or equipment problem solving service that often involves some 3D printing.
Demand for individualised solutions is driven mainly by people, users, customers, (participants), sometimes by OTs or Physios. Most often, local equipment sellers prefer to sell solutions that they already have supply agreements for. If your local equipment showroom has said they do not have what you want, please consider asking for a consult to see if what you need can be made by 3D printing or other production processes.
If you are a participant in the NDIS the cost can often be covered by low-cost assistive technology budget, capital supports budget, or capacity building budget, or even core funds for low cost items. Please enquire and we can make an estimate and give quotes for future funding if required. Note that David is an experienced physio with more than 10years in the disability sector, a prescriber for all types of wheelchairs and other equipment and can consult on off-the-shelf solutions also.
Get in touch if you have a requirement or an idea that you would like to explore. Read on for some tangible examples:
Power Assist adapter
Mr A wanted power assist wheels fitted to his favourite manual wheelchair. He consulted with an OT who said not possible and instead prescribed him a new manual wheelchair + power assist. NDIS paid and the new equipment was delivered 6 months later. But this was not what Mr A wanted and the new chair sat in the corner for a couple of years collecting dust.
When Mr A met with David, he asked if the power wheelset could be fitted to his preferred chair. The manufacturer did not have parts to suit so a suitable adapter was designed and 3D printed with a strong plastic. The function was tested for a few weeks, then parts produced in metal, CNC machined from the working 3D model. Works great; client happy; cost a LOT less than a new wheelchair.
Heavy duty wheelchair forks
Mr B relies on a heavy duty powered wheelchair for all his mobility. He can’t afford breakdowns but because of ataxia he is hard on his equipment and limits are pushed. He was having problems with the front wheels: the alloy forks were frequently getting bent. The supplier workshop replaced the forks several times in quick succession but the same damage kept recurring. No alternative, stronger parts were available from the manufacturer or supplier. These repeated repairs cost money, and more importantly Mr B is at risk whenever his chair is broken down. David took measurements from the existing forks, designed a compatible fork and pintle and sent 3D files overseas for replacements CNC machined from strong and resilient CrMo steel. The problem resolved immediately and these CrMo forks have been in service 3 years now. Client is happy, big reduction in breakdowns, and the cost was similar to original parts.
Bonus: including extra axle mounting holes allowed us to adjust wheel size and rake/offset to successfully manage fluttering and other clearance issues for this participant.
Flexible controller mount
Mr C was having trouble with his wheelchair controller mount breaking off his power wheelchair. The supplier workshop replaced parts several times in quick succession, but the problem kept recurring. David used 3D printing to make a tough rubber mounting for the controller: stiff enough that it did not affect the precise controls, but flexible enough that it could take hits and deflect then bounce back. Problem resolved immediately and no further breakages. Low cost.
Gain trainer refit
Ms D used a gait trainer (special walking framework with wheels and a weight support seat) when she was younger, to practice assisted walking, to keep her legs strong, this remains important for her standing transfers today. At the start of winter, she wanted to re-use it for exercise in her home but the size wasn’t quite right anymore. Parts for resizing were available at the manufacturer but supply lead time was 3-4 months, plus any funding delays. A complete replacement was considered, although not the most cost effective option. Waiting for factory parts would see the whole timeframe lost so instead: alternative expansion parts were designed for her old device and 3D printed with strong plastic. The gait trainer was up and working in just 2 days and Ms D used it all winter with great success. Total cost for the refit was less than the quote for original factory parts. Money and time very well spent!
Cup holder
Mrs E needed a custom cup holder. The system that was supplied with her power wheelchair was not working for her. Making a holder that’s specific for her configuration allowed removal of several parts compared to the original adjustable device. Simpler, more reliable, just for her.
Superficially, this example seems almost trivial but speaks to the difficulty of making a device that is one size fits all. Often in the mainstream marketplace, products can be designed to work well for around 95% of users. In the disability sector this is not always possible. In the attempt to fit a large variety of users, mass-produced products are often more complicated or expensive and still don’t fit perfectly for every individual. Sometimes, a custom, or individualised solution is better.
Clavicle fracture brace
David worked with a leading orthopaedic surgeon to develop an effective clavicle fracture brace. This example is not individualised, but is designed to fit a wide variety of patients. It is in early stage trials in hospitals and clinics now. Initial production via 3D printing with the design optimised for this.
