Clinical Workflow

At Korthotics, all 3D printing is completed in-house through our central fabrication service. Using CT scan data and advanced CAD technology, we create custom thoraco-lumbo-sacral orthoses (TLSOs) that deliver a precise, patient-specific fit and optimal spinal support.

Manufactured from high-strength materials using advanced 3D printing, our braces provide a lightweight, durable, and streamlined alternative to traditional fabrication methods—enhancing both comfort and clinical performance.

Our approach supports a wide range of spinal orthoses, including:

  • Scoliosis Braces – Boston-style and Chêneau-style, individually tailored to each patient's unique spinal curvature

  • Thoraco-Lumbo-Sacral Orthoses (TLSOs) – for trauma care and post-operative stabilisation

  • Lumbo-Sacral Orthoses (LSOs) – for targeted support and rehabilitation

By leveraging 3D printing technology, we deliver highly customisable, lightweight, and visually appealing designs that improve clinical outcomes while supporting patient comfort and compliance.

Here is the process of a 3D Printed TLSO:

  

 

1. Diagnosis 

A diagnosis should be made by a neurologist, orthopaedic surgeon, or trauma specialist—specifically a clinician with expertise in spinal management.

If the spine is considered suitable for conservative (non-surgical) treatment, the specialist, in collaboration with the orthotist, will recommend the most appropriate orthosis. The aim is to provide stability while also considering factors such as patient compliance, brace weight, and overall clinical outcomes.

Once an orthosis is prescribed, the orthotist obtains CT scan data to begin the design and fabrication process as part of the patient’s conservative management plan.

2. CT Image

A panoramic computed tomography (pan CT) scan forms the foundation for accurate anatomical modelling. The imaging protocol should capture the entire spinal region of interest, including adjacent soft tissue structures.

For high-resolution detail of the bony anatomy, axial slices of 1 mm thickness are required. The resulting DICOM (Digital Imaging and Communications in Medicine) files are then exported for digital processing.

In most trauma cases, the patient’s arms are positioned above the head to minimise streak artefacts in the chest and abdominal regions. A secondary white-light scan may also be performed in the supine position, with the shoulders relaxed and depressed, arms abducted, and hands pronated onto the bed. This positioning clears the arms away from the torso and latissimus dorsi region, providing additional anatomical reference.

3. CAD Design

Segmentation of the soft tissue and spinal anatomy can be performed using specialized medical imaging software such as RadiAnt DICOM Viewer. The process involves isolating the epidermis and skeletal structure from the surrounding environment. The segmented volumes are then converted into a 3D mesh (STL) suitable for computer-aided-design (CAD).

The exported mesh may need further optimisation to remove artifacts and improve surface quality. CAD software is employed to refine the model to represent the patient in an upright position. The spinal orthosis is designed to factor in spinal support, load distribution and mechanical stresses.

4. 3D Print

Once the orthosis design is finalised, slicing software is used to generate printer instructions (G-code) for additive manufacturing.

The brace is fabricated using a Fuse Granulate Fabrication (FGF) 3D printer, with polypropylene co-polymer applied at a 3–4 mm wall thickness to achieve the ideal balance of strength and flexibility.

Depending on the size and complexity of the orthosis, the printing process typically takes 8 to 12 hours to complete.

5. Fitting

The finishing process follows conventional orthotic methods, including the removal of support structures, edge polishing for skin comfort, and the integration of closures such as Velcro straps, loops, and chafes. Where required, lining materials may also be added to enhance comfort and support.

Once complete, the orthosis is prepared for patient fitting. Thanks to the accuracy of digital modelling and 3D fabrication, only minimal adjustments are typically needed to achieve a precise, comfortable fit.

For more information, please contact Korthotics on (02)8710 4183 or contact us.