LeoShape Collaborates With Formlabs for 24-Hour Custom-Made Orthopedic Solutions

Leopoly’s LeoShape is a software solution for the orthotics and prosthetics industry which has partnered with Formlabs to offer a new solution for custom orthopedic insole production. This collaboration harnesses Formlabs’ selective laser sintering (SLS) 3D printing technology alongside LeoShape’s digital design platform, which is said to mark a significant milestone in the field of orthotics.

With the aim of delivering superior tailor-made orthopedic solutions to patients, the partnership between LeoShape and Formlabs endeavors to modernize custom orthopedic device production. Their objective is to streamline the process, increase speed and enhance precision to mark a significant milestone in orthotics.

LeoShape’s proprietary 3D design engine, integrated into the LeoShape platform, offers flexibility for designing custom orthopedic and prosthetic devices, including insoles, ankle-foot orthosis (AFOs) and spinal braces. For this particular partnership, the focus is on transforming insole production. By leveraging Formlabs’ Fuse 1+ SLS 3D printers, LeoShape aims to streamline the production process, delivering tailor-made insoles with unprecedented speed and precision.

Digitizing Insole Production With SLS 3D Printing

The company says the SLS 3D printers bring significant advancements to the in-house production of custom orthopedic insoles, offering substantial labor reductions and the ability to deliver tailor-made products within just 24 hours. The technology enables design freedom and minimizes waste, thereby enhancing both efficiency and sustainability in the production of custom orthotics.

The Fuse 1+ showcases the best of Formlabs’ SLS technology — a compact, industrial and scalable 3D printer. Generated off the success of the original Fuse 1 and released in 2022, the Fuse 1+ is now Formlabs’ most powerful industrial SLS 3D printer. The company says the Fuse 1+ has been chosen by more than half the SLS users in the world. Now, this compact contained ecosystem offers rapid SLS at a scanning speed of up to 12.5 m/sec. Known for its high reliability and precision, the Fuse 1+ ecosystem also offers a lower capital expenditure.

Formlabs’ Ecosystem: PreForm Software, Form Sift and Form Blast

The complete SLS ecosystem offers an end-to-end streamlined workflow from setup to finished parts, and is supported by the intuitive, free PreForm software. Postprocessing steps are streamlined with Form Sift and Form Blast. The Fuse Sift has the dual function of cleaning parts and recovering unused powder up to 70%, thereby lowering the cost per insole pair. The Fuse Blast is an easy-to-use, fully automated cleaning and polishing solution, enabling users to achieve professional parts that are clean to the touch in as little as 15 minutes.

“We are thrilled to partner with Formlabs to bring cutting-edge 3D printing technology to the orthotics and prosthetics industry,” says Roland Manyai, LeoShape CEO. “This collaboration allows us to combine LeoShape's expertise in digital design with Formlabs’ industry-leading SLS 3D printers, empowering practitioners to deliver superior custom orthopedic solutions to patients worldwide.”

The LeoShape and Formlabs Partnership

LeoShape and Formlabs launched a free trial campaign in mid-May, offering participants access to LeoShape’s insole editor and three pairs of printed shell samples from Formlabs. The companies say this initiative underscores the commitment of both companies to democratize access to advanced digital and manufacturing technologies within the orthotics and prosthetics sector, empowering practitioners to make informed decisions that enhance patient outcomes.