Abstract: A three-dimensional subtractive manufacturing system configured for constructing an orthopedic orthosis from a first blank of a plurality of blanks includes a scanner configured to capture a 3D model of a body part of a patient, a central processor configured to receive the 3D model and select the first blank based on the three-dimensional model and a computer numerical control machine configured to receive the computer numeric control programming file and an identification of the first blank from the central processor. The central processor is configured to convert the 3D model into a CNC programming file. The CNC machine comprised of a subtractive manufacturing machine. The CNC machine configured to remove material from the first blank to form the orthopedic orthosis.

Abstract: A scanner system for capturing a three-dimensional model of an object includes a laser and a camera to capture two-dimensional images of the object. The system also includes a tube mounted to a rail, a central processor configured to receive data collected from the laser and the camera and an actuation mechanism configured to move the tube along the rail. The tube is configured to move generally along a travel axis of the rail. The tube includes open first and second tube ends. The laser and camera are mounted inside the tube between the first and second tube ends. The first tube end includes a first continuous ring and the second tube end includes a second continuous ring. A channel extends through the tube between the first and second rings positioned adjacent the rail in an assembled configuration.

Abstract: A 3D printed cast or splint for application to a patient's body to immobilize a body part includes first and second shell portions configured to conform to at least a portion of the body part. The first shell portion has a distal end, a proximal end, opposing interfacing edges, a plurality of venting holes and a first engagement mechanism positioned proximate one of the opposing interfacing edges. A reinforcement portion extends between the proximal and distal ends. The second shell portion has a distal end, a proximal end, opposing interfacing edges, a plurality of venting holes and a second engagement mechanism positioned proximate one of the opposing interfacing edges. The first engagement mechanism interacts with the second engagement mechanism in a mounted configuration to facilitate mounting of the first shell portion to the second shell portion.