Introduction: After an orthotic is 3D printed, it undergoes a series of post-processing steps to enhance its appearance, durability, and functionality. Depending on the final assembly, these finishing touches could make a significant difference in patient satisfaction and long-term wear. This week in our campaign we’ll explore the most common post-processing techniques used for 3D printed orthotics!
Dyeing: Dyeing is a common technique used to color the orthotic. Many orthotics start out as grey or white, but dyeing allows clinicians to offer custom colors, which can enhance aesthetics and patient preference.
Benefits: Adds a more complete look, can be customized to patient preference.
Drawbacks: Requires additional time and equipment.
Vapor Smoothing: Vapor smoothing is used to create a smoother surface finish on the orthotic. This is especially useful for materials like PA-12, which can have a slightly rough texture after printing.
Benefits: Smooth, polished finish, a sealed easy to clean surface.
Drawbacks: Not all materials are compatible with vapor smoothing.
Vibratory Tumbling: Vibratory tumbling is another method for smoothing the surface of the orthotic. The orthotic is placed in a machine with small media (such as stones or ceramic) that gently polishes the surface.
Benefits: Effective for large batches, smooths out imperfections.
Drawbacks: Time-consuming, may not achieve the same finish as vapor smoothing.
Raw Finish: Some orthotics are left with a raw finish straight out of the printer. While this is the fastest option, it may not provide the same level of aesthetic or comfort benefits as other post-processing methods.
Benefits: Quick, no additional processing required. May be completely fine, if the orthotic is being covered with layers
Drawbacks: Rougher texture, may be less comfortable for patients.
Conclusion: Post-processing is an essential part of the 3D printing workflow, ensuring that the final orthotic meets both functional and aesthetic standards. Whether through dyeing, smoothing, or leaving the orthotic in its raw state, these techniques allow clinicians to tailor the orthotic to the specific needs of the patient while enhancing the overall quality of the product.
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