Abstract: Embodiments of the provided technology relate to methods, devices, and systems that drive a transfer of the digital profile of residual limb contours to a thermoplastic article such as a prosthetic socket strut. A method of reforming a thermoplastic article to assume a desired shape, such as a contour that replicates or is complementary to the contour of a body portion, may include heating a thermoplastic article to render the article malleable. The method may further include placing the thermoplastic article against a molding surface having a desired shape that replicates the portion of the body part. Next, the thermoplastic article may be pressed against the molding surface with a compliant molding press to reform at least a portion of the article into the desired shape. The reformed thermoplastic article may then be removed from the molding surface, the article retaining the desired shape after removal.

Abstract: The technology includes methods and systems for providing a wearable article to a customer, one that conforms to portion of the customer's body. Methods include receiving an acquired digital data set defining a three-dimensional digital profile of the body part; translating the digital set into instructions for fabrication of the wearable article; and sending the instructions for fabrication of the wearable article to a fabrication site. Instructions for fabrication of the wearable article are operable to select from inventories components or materials to be used in the fabrication of the wearable article, and are operable to fabricate or reshape the components or materials through implementation of a rapid manufacturing machine. A finished article assembled therefrom conforms to the body part.

Abstract: A method is described for fabricating a sequential series of orthopedic devices custom designed to change a configuration of a body part of a patient from a pretreatment configuration to a treated configuration. The method involves receiving digital data representing the body part of the patient in the pretreatment configuration. The method continues by generating, using the digital data, a sequential series of digital 3D body part models, including at least an initial body part model representing the pretreatment configuration of the body part, a final body part model representing the treated configuration of the body part, and at least one intermediate body part model representing the body part in an intermediate configuration between the pretreatment and treated configurations. The method further involves fabricating the sequential series of orthopedic devices from the sequential series of digital 3D body part models.

Abstract: Embodiments of the provided technology relate to methods, devices, and systems that drive a transfer of the digital profile of residual limb contours to a thermoplastic article such as a prosthetic socket strut. A method of reforming a thermoplastic article to assume a desired shape, such as a contour that replicates or is complementary to the contour of a body portion, may include heating a thermoplastic article to render the article malleable. The method may further include placing the thermoplastic article against a molding surface having a desired shape that replicates the portion of the body part. Next, the thermoplastic article may be pressed against the molding surface with a compliant molding press to reform at least a portion of the article into the desired shape. The reformed thermoplastic article may then be removed from the molding surface, the article retaining the desired shape after removal.