3D Printed Orthosis Prototype (Not for Medical Use!)




About: We make innovative digital fabrication machines. Our ZMorph 2.0 SX Multitool 3D Printer is one of the most advanced desktop rapid prototyping devices on the market with interchangeable toolheads enabling one...

This 3D printed rehabilitation orthosis was developed and fitted to a specific person’s hand and probably won’t fit other people unless the source files are properly adjusted in 3D modeling software. ZMorph and Eliza Wrobel who designed this device are releasing these source files only for educational and hobby non-commercial use.

This is not a certified rehabilitation device and shouldn’t be used as one!

The free package contains 58 files that enable 3D printing of all parts needed to assemble the 3D printed rehabilitation orthosis working prototype.

After unzipping the package there are folders dedicated to all functional sections of the orthosis. Follow the next steps and check the Assembly Guide for details on how to connect specific parts.

You can also read more about the making of 3D printed rehabilitation orthosis on our blog.

Enjoy and remember that any type of medical or other commercial use is prohibited!

Step 1: 3D Printing From STL Files

STL files can be easily transformed into G-codes in 3D printing software and prepared for printing. Smaller parts can be printed in the required number of copies - just multiply them in your 3D printing software.

You can also open several files and put them on a worktable in 3D printing software. We used free Voxelizer software and then printed the entire prototype on ZMorph 2.0 SX Multitool 3D Printer.

We recommend using ABS filament for the entire device.

In the next step, you can find the number of copies of each part you need for assembling the device.

Step 2: Number of Parts That You Need to Assemble the Device

In the Assembly guide, you can find that number + letter in the name of the file represents a certain part and their position in the device:

  • 0 - main husk
  • 1 - finger 1
  • 2 - finger 2
  • 3 - finger 3
  • 4 - finger 4
  • 5 - finger 5
  • 6 - lever mechanism
  • 7 - lever pin

Total number of copies needed to assembly the device:

  • g - 18 copies
  • h - 5 copies
  • I - 4 copies + 1 copy of 5i for thumb
  • k - 5 copies
  • l - 4 copies
  • 7 - 2 copies

If not listed above, then every other part requires only one copy.

We recommend to print the main husk upright in a closed machine. This proved to be the most effective way to print this big part fast and without cracks.

Step 3: Finishing Touches

When your parts are printed you should remove the support with a sharp knife and clean softly with sandpaper.

Use acetone to give them additional polish too.

The only non-printed part that can be added is a Velcro strap in order to fasten the orthosis around the hand but it’s totally optional.

You can also read more about the making of 3D printed rehabilitation orthosis on our blog.

Enjoy and remember that any type of medical or other commercial use is prohibited!



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8 Discussions


1 year ago

Hello, it's possible to have the Solidworks files? I want to make some changes to adapt to a child. Tkx.


1 year ago

What were the dimensions of the persons hand it was modeled after?


2 years ago

When importing set, they are all on top of each other. Is there a way to set the Voxelizer settings to import the pieces all flat on the surface, so they can be printed together (the finger parts, not the main husk)?

1 reply
ZMorph DTSNewCanaan

Reply 2 years ago

You can use auto-align option, it will place the objects over the table.

ZMorph ynjirufeng

Reply 2 years ago

They're in a ZIP package at the beginning of the article.


2 years ago

Nicely done! It gives me hope for the future to see people using 3D printing for practical, useful work.


2 years ago

Great work, Thank you