Fused Filament Fabrication for External Medical Devices

Fused Filament Fabrication (FFF) is the most commonly used additive manufacturing process primarily used to build polymer-based components. FFF finds wide applications in various fields, like—prototyping, tooling, automotive, medical, etc. Among them, the applications of FFF is expanding widely in medical sector mainly due to the customization freedom offered by the technology complying with the unique shape, size and clinical requirement as opposed to conventional manufacturing techniques. The development of orthoses and prostheses are the two major applications of FFF for external medical devices. Orthoses devices are used for either the correction or restoration of the functionality of organs, while prostheses are artificial devices/appliances used for replacement of natural body parts lost or damaged due to illness or injury. However, there are certain challenges associated with the development of accurate medical devices using FFF due to several process-induced limitations. This chapter briefly introduces the FFF process and subsequently focus on its various applications to develop external devices in the medical sector, like—orthosis and prosthesis. It also elucidates the development of bionic prosthesis. The various stages involved in the development of customized medical devices using FFF is discussed. The chapter also addresses the various issues associated with the deployment of FFF to build medical devices. Case studies and recent advances associated with the development of customized orthosis and prosthesis are also included in the chapter. This chapter will serve as quick-start for novices to appreciate the innovations with FFF technology and as a compiled reference document for practising researchers.