![]() There was a progressive improvement in subjective feedback through each iteration at sites of discomfort and overall comfort score. A total of four prototypes were produced with each iteration being improved based on patient and clinical feedback. The 3D patient scan was validated against actual measurements to ensure accuracy of measurements. The workflow includes algorithms to relax geometry, distribute material efficiently and for variational cutting of orthosis padding material. The workflow was developed to generate 3D printable geometry from obtained 3D scan data. The workflow was developed to design and fabricate a bespoke device for this patient with no viable alternative therapy. All traditional and commercial approaches to helping the patient’s cervical instability and resulting ‘head-drop’ had previously failed, with associated progressive deterioration in the patient’s clinical state and posture. The workflow is applied to a clinically relevant translational case study in a patient with a neurological disorder and complex clinical needs. This study demonstrates the development and application of a novel workflow for designing and fabricating orthoses, using a combination of 3D scanning and 3D printing technologies.
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