Customised solutions for exceptional challenges
Every day, we set ourselves the task of developing customised solutions for special requirements. A particularly good example from our day-to-day work shows how we have realised an innovative product for a specific orthopaedic problem together with our partner: A patient regularly bites the nursing staff, which has already led to serious injuries. Our challenge was to design an orthosis that not only protects the patient but also the nursing staff and provides a comfortable solution for the patient that is suitable for everyday use.
Analysis: Right approach is key
In such cases, many resort to Plexiglas ice hockey face masks. Although these offer effective protection, they are often rejected by patients due to their heavy weight and restricted vision. This is where our expertise in orthopaedic design comes in: Our mission was to develop reliable protection that is both lightweight and bearable for the patient. With these requirements in mind, we decided to use our EpiPro helmet as the basis. The helmet can be customised and is therefore ideal for this application. The focus was on developing a closed mouth area that prevents biting without unnecessarily restricting the patient’s field of vision.
Concept: Unique challenges, customised solutions
The actual development work began with the customisation of the helmet. In order to protect more of the head, we designed a slightly more closed helmet design with an open structure, which was made from the lightweight but extremely stable material PA11. The mouth visor was particularly important: it was designed to be completely closed, while the field of vision remained as open as possible to ensure a high level of protection and comfort. One of the biggest design challenges, however, was the chin strap: Instead of a simple standard fastener, we developed an innovative frame with a secured fastening mechanism. This fastener works via a printed spring mechanism that can only be opened using specific motor skills. As the patient does not have these motor skills, the helmet remains reliably secured. This not only effectively protects the carer, but also ensures that the patient can only remove the device with assistance.
Realisation: Perfection down to the smallest detail
Our technicians worked closely with our partner to realise the project. Using various CAD programmes and based on the scans made as part of the patient analysis, we developed all the components down to the tenth of a millimetre and had them printed externally. We then assembled the parts into a ready-to-use unit. The on-site fitting confirmed the success of our work: the helmet offers the nursing staff reliable protection while at the same time giving the patient the greatest possible freedom of movement and an unrestricted field of vision. It is light, comfortable and clearly superior to conventional solutions.
Conclusion: A win-win situation for everyone involved
This example impressively demonstrates how crucial a customised and creative orthopaedic design is. Standard solutions often fail to meet special needs and cannot fulfil the specific requirements of patients and their environment. Through precise analysis, an innovative concept and careful implementation, we succeeded in creating a solution that is not only safe, but also comfortable and suitable for everyday use.