ADAPTBRACE - PROGRAMMABLE ORTHOSIS

Technology Partner |

Fraunhofer IWU

Sector |

Healthcare Technology

Year |

2023 - 2024

Project Type |

Research Prototype & Trade Fair Demonstrator

THE CHALLENGE

Fraunhofer's patented Wire-Encapsulating-Additive-Manufacturing (WEAM) technology needed tangible use-cases to demonstrate its potential to decision-makers across industries. I identified orthopedic braces as an ideal application: conventional braces face a fundamental limitation where even custom-made devices rarely achieve perfect fit, and the body's natural changes during healing can render them ineffective or harmful. Traditional manufacturing methods make adjustments costly and time-consuming, requiring complete replacement when patient needs evolve. This problem-solution fit made orthopedics a compelling demonstrator for showcasing WEAM's adaptability capabilities to potential adopters in medical and beyond.

Traditional orthopedic manufacturing showing fit limitations that identified the use-case opportunity. (Photograph during manufacturer interview)

Initial concept development sketches.

THE innovation

I developed AdaptBrace as a research demonstrator proving how programmable materials solve healthcare's customization challenge. Using Wire-Encapsulating-Additive-Manufacturing (WEAM) technology in collaboration with Fraunhofer, the orthosis demonstrates three revolutionary capabilities:

Universal flat-pack production enabling cost-effective manufacturing
On-site thermoforming for patient-specific fit without specialized equipment
Readjustment capability as treatment progresses, eliminating replacement costs

The two-layer system—flexible TPU inner for comfort, thermoresponsive PLA outer with integrated heating wires—proves industrial viability while maintaining the adaptability healthcare demands.

Adaptive orthosis concept showing gyroid structure core, integrated heating wire system, and custom-fit application. (Rendering)

Functional prototype demonstrating WEAM technology: flat component (left) and thermoformed result (right).

THE DEMONSTRATION STRATEGY

AdaptBrace transforms Fraunhofer's abstract WEAM technology into a tangible experience. Visitors see and feel the transformation from flat component to custom-fitted orthosis through simple heat application—making the technology's adaptability potential immediately clear to decision-makers across medical devices, consumer products, and industrial applications without requiring technical explanations.

Final adaptive ankle orthosis prototype with integrated heating contacts for on-demand adjustment. (Photo: Sascha Linke)

IMPACT & VALIDATION

Research Recognition:

Published in IEEE Xplore and 2024 International Conference on Integrated Systems in Medical Technologies
Exhibited at FormNext 2024, leading international manufacturing exhibition
Featured in Merlin Magazine by smart³ Innovation Network
Collaboration with Fraunhofer Institute demonstrating industrial research credibility

Business Relevance:
This project validates my ability to bridge academic research and commercial communication. Medical device companies struggle to demonstrate abstract manufacturing advantages to clinical decision-makers. AdaptBrace proves how I transform complex technologies into demonstrations that healthcare professionals understand immediately—the same challenge your technical team faces when communicating with non-technical buyers.

AdaptBrace exhibited at FormNext 2024, demonstrating Fraunhofer's patented WEAM technology capabilities.

DEMONSTRATOR POTENTIAL

Ideal for medical technology exhibitions, healthcare digitalization events, and personalized medicine conferences where companies need to make mass customization concepts immediately understandable to clinical and administrative decision-makers.

TECHNICAL SPECS

Materials: TPU (flexible layer), PLA with integrated heating wires (structural layer)
Technology: Fraunhofer WEAM 3D printing
Scalability: Universal component manufacturing → custom fit delivery model
Applications: Orthopedic braces, medical footwear, assistive devices