Case Study - Dust Forge

Researchers from Flinders University are collaborating with DustForge 3D to accelerate the clinical readiness of Selective Laser Sintering (SLS) 3D-printed ankle–foot orthoses (AFOs) by developing and validating novel, application-specific test methods and using them to evaluate next-generation 3D-printed materials for this high-demand clinical device.

While SLS enables highly customised geometries and scalable production, the sector lacks fit-for-purpose evaluation protocols that replicate the mechanical demands experienced by AFOs in real-world gait, including cyclic loading, durability, and failure behaviour in critical regions.

While SLS enables highly customised geometries and scalable production, the sector lacks fit-for-purpose evaluation protocols that replicate the mechanical demands experienced by AFOs in real-world gait, including cyclic loading, durability, and failure behaviour in critical regions.    

The outcome will provide a repeatable evidence base for performance and safety, accelerate translation into clinical practice, and position DustForge 3D as a trusted, go-to manufacturing partner for clinics seeking to adopt 3D printing for high-quality, patient-specific AFO production.   

Researchers:

• Dr Rami Al-Dirini