Bracesys is a modular orthopaedic brace system developed by Osteoid. It offers an alternative to traditional static braces and plaster casts. The system uses a patented structure that clinicians can adjust directly to a patient’s body. This allows for on-site customisation without the need for casting. The adjustable design helps improve fit accuracy and reduces fitting time. It also supports better hygiene, as it avoids single-use casting materials. Because the brace can be adapted during treatment, it can respond to physical changes over time. This flexibility can reduce the need for repeated replacements.

Digital Design And Additive Manufacturing

Bracesys relies on a digital workflow that combines scanning, AI-supported design tools and additive manufacturing. Designers create each brace using patient-specific data. 3D printing then produces the components with a high level of precision.

This production method shortens lead times and limits manual adjustments. It also supports consistent quality across multiple units. For product and industrial designers, the system shows how parametric design and digital fabrication can enable mass customisation. The modular setup allows designers to combine standardised parts with individual adjustments.

Reusable Structure And Material Efficiency

The system focuses on reuse rather than disposal. Conventional orthopaedic braces often rely on materials that clinicians discard after a single treatment phase. Bracesys uses modular elements that can be reconfigured or reused when needed. This approach can extend product lifespan and reduce material use.

Source & photos: Osteoid