Brace Yourself: How Cascade Orthotics Uses 3D Printing to Transform Patient Care
- jonathang22
- 2 hours ago
- 4 min read
For over 30 years, Cascade Orthotics has been a trusted name in custom orthotic care in Calgary. Best known for their work in spinal orthotics, they've continued to grow and adapt by expanding their services and embracing the latest technologies. We caught up with Jeff Wright to hear more about Cascade’s journey, their day-to-day work, and how they’re using modern tools to make a real impact on patients' lives.
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Getting Started and What Drives Them
Can you tell us a bit about how Cascade Orthotics got started and what made you want to get into this kind of work?
The business has been around for about 30 years. I’d say Cascade is most known for providing spinal orthotic care. We deal with a lot of trauma related to spine fractures and scoliosis. Even though we do a lot of other types of orthotics and bracing, that’s probably what we’re most known for.
Personally, I was drawn to the field because it brings together a lot of different disciplines. I liked the idea of applying anatomy, materials science, and biomechanics. I also enjoy working with advanced technology like 3D scanning and CAD, and being able to use that to help people.
How have things changed at Cascade since it first opened?
In the ten years I’ve been involved, we’ve definitely broadened what we do. While we still do a lot of trauma spinal work, we now provide a wider range of orthotic services. We also work with a bigger variety of patients, from kids to seniors.
What values or goals guide your team in how you treat patients?
We really focus on offering a modern approach to orthotic care. Our team considers ourselves early adopters of 3D scanning, CAD design, and digital fabrication tools like carving and 3D printing.
Services and Patient Care
You offer a wide range of orthotics. What kinds of conditions do you usually treat?
I like to describe it as head-to-toe bracing. I always joke that we do everything except teeth, since people often mix us up with orthodontists when we say we’re orthotists.
Some of the most common conditions we see include stroke, spinal cord injury, multiple sclerosis, spina bifida, arthritis, and traumatic fractures.
How do you make sure each device is really tailored to the individual?
Most of what we do is custom-made. The design process is a mix of clinical experience, patient feedback, and knowledge of what’s considered best practice for the specific type of orthosis that’s needed.
Do you work with other healthcare providers as part of your care process?
Yes, quite regularly. Orthoses are typically prescribed by general physicians or specialists. Many of the people we work with also see physiotherapists or occupational therapists. When we’re working with inpatients, we rely a lot on nurses and hospital staff too.
Tools and Technology
You’ve mentioned using things like 3D scanning and printing. How have those changed the way you work?
We rely heavily on digital workflows for a few key reasons. For one, they allow us to be more efficient. We don’t need to deal with heavy plaster casts, which is especially helpful when working with torsos or large limbs. It also saves us from a lot of the hands-on manual work like casting, filling casts, and modifying by hand.
We also find the digital tools are also more accurate. Our 3D scanners have a high degree of precision, and CAD software helps us make very exact design adjustments. Then with 3D carving and printing, we’re able to fabricate devices that really maintain that accuracy all the way from scan to final product.
3D printing in particular has been a big step forward. It gives us design flexibility that we don’t have with traditional vacuum forming. That means we can make devices that look and perform differently.
What do you like about using PA-12 nylon in your devices?
We like PA-12 and the MJF process because of how consistent and strong it is. It has a high level of isotropy, which is important for durability. We can drill into it, attach components with rivets, and even make some adjustments after it’s been printed.
Working with Patients
What do you do to make sure your patients have a good experience?
We always try to understand what their goals and expectations are. Then we match that with our own knowledge and experience to come up with a solution that we’re all confident in. Whenever possible, we like to give patients a few different options and let them decide which direction to take.
How do you gather feedback and use it to improve?
That’s something we’ve started focusing on more recently. We just launched our social media platforms to help share more about what we do and also to encourage patients to show us what they’re doing with their orthoses. We’re also launching a formal feedback program within the clinic.
Looking Ahead
You’re based in Calgary. Do you do much community outreach or public education?
That’s something we’re hoping to build on through our social media presence. We want to raise awareness about orthotic care. We also provide in-service or education sessions to different hospital units to increase their knowledge about working with orthotic inpatients.
What’s next for Cascade Orthotics? Are there any new tools or services you’re excited about?
We’re always keeping an eye out for new products and technology. Right now, we’re interested in adding a degree of automation to our workflow in order to make our design process even more efficient. We also think that could help us grow our 3D printing capabilities.
How do you stay on top of what’s new in the orthotics field?
Our clinicians attend different conferences focused on orthotic care. We also meet with product reps who keep us up to date with new materials and components. And, we talk with our colleagues in the field to learn what’s working for them.
We love proudly supporting forward-thinking clinics like Cascade Orthotics with precise, production-grade additive manufacturing. Contact us to explore how we can support your custom healthcare components!
