From Plaster to Print: How 3D Printing Transforms Prosthesis Fabrication

By Abby Koch (EIT) - VHP Mechanical Engineer, BCIT Clinical Prosthetics & Orthotics Student

Prosthesis fabrication has long relied on traditional methods: plaster molds, hand sculpting, vacuum forming, and highly skilled technicians.

As digital tools become more accessible, a 3D printed workflow for fabrication has emerged. At Victoria Hand Project (VHP), we’re expanding global access to prosthetic care, and 3D printing helps us reach communities with limited resources.

Traditional Methods in Prosthesis Fabrication: A Hands-On Art

1. Traditional fabrication of a prosthesis begins with shape capture. The patient’s residual limb is wrapped in plaster bandages to create a negative cast. 

2. The negative cast is filled with plaster of Paris to create a positive mold.

3. The positive mold is hand-modified by a skilled prosthetist and finally, 

4. Thermoplastics or laminates are vacuum formed or resin-infused around the mold to produce the final prosthetic socket.

Figure 1: Traditionally fabricated prosthesis https://limbtechgroup.com/upper-extremity-prosthesis/

In contrast, 3D printing is an additive manufacturing process that builds objects layer by layer from a digital file. In prosthesis fabrication, this enables rapid prototyping, anatomical customization, and improved affordability for patients.

The Digital Prosthesis Workflow at a Glance:

1. 3D Scanning: The residual limb is scanned to capture its shape.

2. Digital Modelling: This scan is imported into CAD (Computer-Aided Design) software to model the prosthetic device.

3. Slicing: The digital model is converted to G-code for printing instructions. 

4. 3D Printing: The 3D printer reads the G-code and material is extruded layer by layer to form the prosthetic part. 

5. Post-Processing and Assembly: The print supports are removed and the part is sanded and assembled. 

With step-by-step manuals and on-call support from the VHP technical team, our clinical partners are empowered to 3D print and fit Victoria Hand prostheses in their own country. 

Not Just a Tool, But a Team Effort

We believe 3D printing is a tool that, when paired with clinical judgment and technical expertise, can expand a clinic’s capabilities. 

As S. Raschke reflects, 

“3D printers themselves do not do research or provide clinical care… they must be paired with skilled persons engaged in the prosthetic or orthotic design and provision process.”.

Final Thoughts

Digital prosthesis workflows don’t eliminate the need for traditional skills, instead, they expand what’s possible. 

At VHP, we’ve seen how 3D printing enables clinics around the world to create custom prostheses quickly and affordably, even without extensive lab infrastructure. 3D printing integration is a step toward more equitable care, driven by local capacity and innovation.