3D tech takes a 'step' in the right direction

Norwich-based (UK) medical practice, BxClinic, is the first clinic in the UK to launch an in-house 3D printer to manufacture medical orthotic insoles for patients. As part of a nationwide project designed by FootHealth, BxClinic is pioneering the first clinical trials across the UK, bringing this advanced medical technology to patients in Norfolk. 

Plastics and 3D print engineering specialist Kieran Carew, along with lower limb specialist Ian Sadler, are leading 3D prescription prototyping and advancing 3D insoles. These insoles are designed to improve the health and quality of life for people suffering lower limb pain and injury. 

Carew has an extensive background in materials engineering and the medical device manufacturing industry. Former special forces medic Sadler has more than 15 years experience working with industry leaders to improve orthotic and footwear technologies. Carew is developing a robust 3D printing process to bring distributed manufacture to the musculoskeletal health industry, while Sadler is developing and trialing the prescription process. Ultimately, these prescription shoe inserts will help patients walk and run pain free, providing both cushioning and support — the ‘holy grail’ for your feet. 

“3D printing has been around for a while now, but the printable materials were too brittle and absorbed moisture, so not ideal for making shoe insoles. We have experimented with various polymers looking for ones that can be both soft and hard in the same insole, while taking up less space in shoes adding almost limitless possibilities for clinicians to design devices for their patients,” says Carew.

This technology will allow local manufacturing of these complex medical devices, significantly reducing the carbon footprint currently dependent on an international supply chain. Furthermore, the 3D additive manufacture process reduces waste materials, as well as the environmental impact of large-scale manufacture enhancing bespoke design for each individual patients needs. 

“With this technology, we’ll be able to change the way we help our patients, supporting those suffering from shin splints, knee pain or bunions, to back aches and hip pain - while creating business networks and jobs locally in Norfolk,” says Carew,