Future Orthopaedics: From Plaster Casting to 3D
From Plaster Casting to 3D” is a strategic initiative within the Department of Orthotics and Prosthetics at Sahlgrenska University Hospital.
Name of the strategic project
Future Orthopaedics: From Plaster Casting to 3D
When was the project initiated?
2023
Do you have any academic affiliations or collaborations?
Yes. The project includes collaborations within several research and innovation areas related to orthotics, prosthetics, sustainability and digital manufacturing.
Current collaborations and funding initiatives include:
- Material reuse, biomaterials and sustainability projects, including applications to the Kamprad Family Foundation
- Testing of AI-driven tools within digital orthotics and prosthetics, including applications to the Swedish Shoe Industry Foundation for Research and Development
- Clinical studies of innovative solutions together with UK partners through the Vinnova-supported project “Capacity-building collaboration for clinical studies of 3D-printed orthopaedic assistive devices”
- Participation as a clinical partner in a European Horizon application on low-value care together with Jönköping University
The project also collaborates with organisations including RISE, Chalmers Industriteknik and Sahlgrenska Science Park.
Describe the project
“Future Orthopaedics: From Plaster Casting to 3D” is a strategic initiative within the Department of Orthotics and Prosthetics at Sahlgrenska University Hospital. The project is anchored within hospital leadership and regional governance structures.
A completed feasibility study formed the basis for a management-directed investment of SEK 3 million over three years, beginning in 2025. The initiative includes investments in technical equipment, digital workflows, staff training, and new standards and quality protocols.
Implementation is taking place stepwise, from pilot projects to full operational integration, while care and production processes are continuously adapted. In the long term, the model is intended to scale regionally and contribute to preparedness, knowledge-sharing and the development of Swedish orthopaedic technology.
Describe your solution
The project aims to transition orthopaedic production from traditional plaster casting and manual methods to digital manufacturing using 3D scanning, CAD and 3D printing technologies.
The goal is to improve accessibility, quality and efficiency while also strengthening sustainability and the working environment for healthcare professionals.
Digital workflows replace plaster casting and manual production steps. The patient’s anatomy is scanned digitally, assistive devices are designed with high precision in CAD software, and products are manufactured through additive manufacturing.
This process enables shorter lead times, more consistent fit and fewer adjustments or remakes. Patients benefit from faster delivery, improved comfort and increased safety, while healthcare services gain greater standardisation, resource efficiency and scalability to meet increasing care demands.
At the same time, the approach reduces material waste, environmental impact and the physical strain placed on staff.
What problem are you addressing?
The Department of Orthotics and Prosthetics at Sahlgrenska University Hospital is a specialist healthcare service within the Västra Götaland Region, responsible for providing patients with individually adapted orthopaedic assistive devices.
The service plays a critical role in supporting mobility, function and quality of life, but currently faces significant challenges.
Demand for orthopaedic services exceeds available capacity, resulting in waiting lists and extended waiting times. For some patients, delays can lead to deteriorating function or secondary medical complications.
These challenges are further amplified by an ageing population and a shortage of certified orthopaedic engineers.
The COVID-19 pandemic also highlighted the vulnerability of existing production models and the need for more robust and flexible workflows.
Today, orthopaedic production still relies heavily on traditional manual methods such as plaster casting, hand processing and physical moulds. These methods are time-consuming, labour-intensive and highly dependent on individual craftsmanship, resulting in variations in quality and fit. They also contribute to higher operational costs, material waste and ergonomic risks for staff, including heavy lifting, repetitive tasks and chemical exposure.
What impact does the project create?
The digital manufacturing process enables shorter lead times, more consistent fit and fewer adjustments or remakes.
For patients, this means faster delivery, improved comfort and increased safety. For the healthcare organisation, the project creates opportunities for greater standardisation, more efficient resource utilisation and scalable production capacity, while reducing dependence on manual craftsmanship and supporting increasing healthcare demands.
What stage is the project currently in?
The project has entered a pilot phase focused on corsets and ankle-foot orthoses (AFOs).
What are you currently seeking to take the next step?
To further develop the initiative, the project has established collaborations with organisations including RISE, Halmstad University, Karlstad University and Chalmers Industriteknik, as well as companies active in the field.
Together, the partners are applying for and planning additional funding initiatives connected to spin-off ideas emerging from the project. These include:
- Material reuse, biomaterials and sustainability
- AI-driven tools for digital orthotics and prosthetics
- Clinical studies of innovative 3D-printed orthopaedic solutions
- European collaborative projects related to healthcare efficiency and low-value care
What future potential do you see for the initiative?
The project is among the first in Europe to implement a fully integrated transition of a public orthopaedic service to additive manufacturing at scale, where the healthcare organisation itself owns and operates the entire production chain.
While 3D printing has previously been tested for individual assistive devices internationally, it remains uncommon for the technology to be fully integrated into routine clinical workflows with full responsibility for quality assurance, processes and long-term operations.
The project therefore creates a practical and scalable model that other orthopaedic services can adopt. It also opens opportunities for deeper collaboration between healthcare organisations through the sharing, development and joint evaluation of digital orthopaedic designs.
The text above is machine translated from a Swedish original.
Contact:
John Alnemo
Projektledare & ortopedingenjör
john.alnemo@vgregion.se
