The future of recovery: 3D-printed supports for your bones

Imagine a medical support device that doesn’t just stabilise an injury, but adapts to your body’s every movement and need.

These kinds of recovery devices - from orthotics that help you walk after an injury, to bone scaffolds that guide new tissue growth after surgery - are usually made in standard shapes and sizes, meaning patients often have to adjust to the device rather than the other way around.

Dr Maedeh Amirpour, senior lecturer in engineering science and biomedical engineering, is working to change that. She’s developing personalised supports using biocompatible 3D-printed frameworks combined with body-safe gels.

Supported by the University’s Research Development Fund, Amirpour and her team are designing these structures to meet the needs of each patient.

"The 3D-printed frameworks act like a backbone for the device, while specifically formulated gels cushion movement and absorb impact," Amirpour explains.

To make sure each design works safely and effectively, the team uses computer simulations to predict how the device will respond to physical forces and the body’s biology.

"By adjusting the porosity of the 3D-printed framework - essentially the size and arrangement of the tiny openings within it - and the properties of the gel, we can fine-tune each device so that some areas are firm and supportive while others are soft and comfortable."

Amirpour says traditional orthotics and scaffolds are usually one-size-fits-all – which means they can wear out quickly, cause discomfort during healing, and in some cases, even create new injuries.

Her approach solves these problems by creating supports tailored to each patient’s body and recovery needs.

"The devices will be stronger, last longer and will be better at absorbing shocks from everyday use, while the gel-scaffold combination is safe for the body and can encourage bone growth and tissue healing," she says.

"Each device can be adjusted for stiffness, flexibility and cushioning, giving patients better, more personalised support instead of relying on standard, rigid devices."

These devices could be used in a range of situations, including after surgery, to support broken or healing bones, for people recovering from injuries, or as part of custom sports equipment to protect bones and joints.

Amirpour says the medical devices would also benefit clinicians and manufacturers.

"Clinicians could prescribe supports that match a patient’s movement patterns and recovery needs, while manufacturers could scale up production of supports that combine advanced engineering with medical care."

Working from the University’s Centre for Advanced Materials Manufacturing and Design (CAMMD), Amirpour is developing the devices alongside Dr Reza Arjmandi (Chemicals and Materials Engineering) and Professor Mark Battley (Engineering Science and Biomedical Engineering).

The team’s vision is to see these next-generation medical devices become part of everyday healthcare and rehabilitation.