Greener technology transforms orthotics care for patients at RJAH

Patients at The Robert Jones and Agnes Hunt Orthopaedic Hospital (RJAH) are set to benefit from faster treatment, fewer hospital visits and a more environmentally friendly service thanks to the introduction of innovative 3D printing technology in the Orthotics Production and Manufacturing Department.

The pioneering digital manufacturing system replaces traditional processes that have been used for more than 30 years at the Oswestry-based hospital, transforming the way custom orthotic insoles are designed and produced.

Made possible through a £167,000 capital investment, the technology will significantly reduce material waste, cut transport requirements and improve sustainability, while also enhancing the patient experience.

Traditionally, orthotic insoles have been created using plaster casts, physical moulds and manual manufacturing processes. The new digital pathway uses 3D scanning technology to capture a patient's foot shape, with insoles then designed digitally and produced using a state-of-the-art 3D printer.

The new system delivers a number of environmental benefits by reducing the use of Plaster of Paris and other disposable manufacturing materials, cutting waste, reducing the transportation of physical moulds between hospital sites, along with patient travel time.

For patients, the technology means a quicker and more convenient service. Initial trials have reduced manufacturing time from around 75 minutes to just 15 minutes – helping to speed up production and improve turnaround times.

The introduction of a secure digital library of patient scans also means exact replacement insoles can often be produced without the need for a further clinical assessment. This will reduce unnecessary appointments, free up clinic capacity for other patients and make life easier for those who travel long distances to RJAH.

Steve Bishton, Orthotics Technical Lead, said: “This is an incredibly exciting step forward for Orthotics and our patients.

“By embracing digital technology, we're not only improving the way we manufacture orthotic insoles, we're also making the service more sustainable by reducing waste and unnecessary transport.

“Most importantly this technology will help us improve patient experience – it's a fantastic example of how innovation can support both better patient care and a greener NHS.”