Innovation in Orthotics: A Groundbreaking Change for Ergona Opava s.r.o.

INITIAL SITUATION

The previously used orthoses had a massive structure that reduced patient comfort. Traditional manufacturing methods resulted in long delivery times and high material consumption, negatively impacting costs.

The weight of the orthosis reached up to 1.75 kg, production was time-consuming, and the total cost per unit was high. In the competitive medical device market, it was necessary to find an innovative solution that would enhance patient comfort while enabling more efficient production.

A market solution needed to:

✔ Reduce the weight of the orthosis and improve its ergonomics.
✔ Accelerate the production process and shorten delivery times.
✔ Lower manufacturing costs to provide a more affordable alternative without compromising quality.

SOLUTION: THE COLLABORATION PROCESS

In collaboration with Brain4Industry experts, an entirely new solution was developed, leveraging advanced digital technologies and additive manufacturing.

Key innovation steps:

✔ Selection of biocompatible materials – ensuring durability, longevity, and patient safety.
✔ Implementation of SLS (Selective Laser Sintering) technology – enabling precise and cost-effective production with minimal waste.
✔ Structural optimization using simulations – redesigning joints and structural elements to enhance the orthosis’s functionality.
✔ Custom-designed joint mechanism – Brain4Industry developed and prototyped an innovative joint that allows adjustable movement range or complete fixation, tailored to the patient’s needs.
✔ The joint was designed and manufactured using SLM technology from stainless steel.

Watch the video case study:

RESULT: WHAT ERGONA OPAVA GAINED FROM THE COLLABORATION

Thanks to an innovative approach and modern technologies, significant improvements were achieved:

✅ Radical weight reduction – the new orthosis now weighs less than 400 g, making it over 75% lighter than the previous version.
✅ Faster production – reduced from several months to just two weeks.
✅ Lower costs – the redesigned orthosis is over 20% more affordable, with a production cost now below CZK 35,000.
✅ Competitive advantage – the enhanced product opens new opportunities for global market expansion.

THE FUTURE OF ORTHOTIC INNOVATION

This successful project demonstrates how digital transformation and additive manufacturing can significantly enhance not only products but also overall manufacturing efficiency. The Brain4Industry approach enables companies to test and implement new technologies without high upfront investment, unlocking further innovation potential.

🚀 Want to innovate too?

Whether it’s medical devices, industrial components, or specialized parts, Brain4Industry can help bring your ideas to life. Contact us today, and together, we’ll find the right solution to drive your business forward!