Ricoh 3D x ORLAU: Transforming Orthotic Care Through Additive Manufacturing Co-Creation
Company:
The Orthotic Research & Locomotor Assessment Unit (ORLAU), based at The Robert Jones & Agnes Hunt Orthopaedic Hospital, NHS Foundation Trust, supports adults and children with mobility impairments through gait analysis, rehabilitation engineering and orthotic innovation.
Challenges
Over time, ORLAU identified limitations in two key clinical tools: the Knee Alignment Device (KAD) used in gait assessments, and the Ankle Contracture Correction Device (CCD), which assists patients with soft‑tissue stretching for rehabilitation. Both legacy solutions were labour‑intensive, ergonomically outdated, and difficult for patients to use independently.
On one side, ORLAU’s existing Knee Alignment Device (KAD) had become increasingly difficult to source, repair and operate. Springs often broke, foam pads offered poor stability, and patients – many with limited mobility – were required to stand for extended periods during setup. Similarly, the traditional Ankle CCD relied on a steel tension loop that was difficult for many patients to manage, creating a barrier to regular rehabilitation routines. 'Donning and doffing' were physically challenging, especially for those with restricted movement.
Both devices required an update that would improve durability, ergonomics and ease of use, while remaining cost‑effective for the NHS.
The Ricoh 3D Resolution
Since 2017, Ricoh 3D and ORLAU have worked closely — sharing expertise, testing prototypes, and applying advanced 3D printing technologies to re‑engineer orthotic solutions for better real‑world performance.
1. Modernising the Knee Alignment Device (KAD)
Ricoh 3D redesigned the device using AM‑optimised geometry, improving patient comfort through a more ergonomic knee cup and enabling clinicians to fit the device while patients remain seated. This sharply reduces stress and time during gait analysis. Thanks to local Multi Jet Fusion production (MJF), lead times dropped from weeks to days, significantly easing pressure on rehabilitation engineering teams.
2. Developing the Ankle CCD Lever Kit
Responding to the need for better usability, Ricoh 3D and ORLAU created an attachable lever‑hinge mechanism that temporarily releases stretching torque—making donning and doffing dramatically easier. The device combines 3D‑printed, machined and off‑the‑shelf components for reliable clinical performance. The lever is manufactured using Nylon‑12 via MJF technology, offering strength, flexibility and durability suitable for daily rehabilitation use.
3. Engineering Optimisation & Material Efficiency
Ricoh 3D’s engineering team applied Finite Element Analysis (FEA) and generative design, reducing weight of the lever by 40%, lowering AM material usage and cutting costs by around 15%—without compromising strength or performance.
Benefits | Award-Winning Innovation
The redesigned KAD earned a TCT Healthcare Application Award, recognising its improved ergonomics, reduced cost, and transformative impact on gait analysis workflows. Both redesigned devices have demonstrated:
- Enhanced comfort for patients with limited mobility
- Faster and easier setup for clinicians, reducing clinical strain
- Smoother, more independent use of the Ankle CCD Lever Kit thanks to the new hinge mechanism
- Improved durability, with device testing exceeding 3,000 operational cycles and a lifespan of more than five years
- Scalable production & distribution, with Beagle Orthopaedic integrating the lever into AFO systems and distributing directly to NHS clinicians and orthotists
"This whole process has shone a spotlight on the potential of 3D printing to unlock the next generation of orthotic innovations, prioritising patient care."
Samuel Oliver
Clinical Engineer, RJAH NHS Foundation Trust
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