3D Printing for Orthotics and Prosthetics
Customization to the patient´s anatomy eliminates the need for implant adjustments, provides efficient fit and enhancing functionality of the damaged or deformed part
Additive Manufacturing for the O&P Industry
BASF Forward AM offers one of the broadest portfolios of high-performance materials, consultancy expertise, simulation know-how, a global printing network and post-processing capabilities - all in the quality known from BASF since 150 years.
Additive manufacturing fabricates custom implants of any complex shape and in the exact geometric feature, which is not previously possible by using traditional manufacturing techniques. Various benefits of additive manufacturing are as under:
- Perfect-fit production depends on the patient´s needs
- Offers unlimited geometric freedom
- Precise setting of desired elasticity
- High bio-compatibility
- Faster availability, shorter build times
- Fully automated and digitalized manufacturing
Real-Life Applications
Discover real life projects and find out more about Additive Manufacturing for the O&P industry in our use cases.

3D Printing Workflow for Orthotics and Prosthetics Professionals
O&P professionals integrate 3D printing to their workflow more and more - read all about a real-life example of a wrist cast.

Mold Improving Fitting and Comfort of ProsFit Prosthetics Sockets
Today amputees requiring prosthetic limbs have to put up with often uncomfortable, poorly fitting sockets. A collaboration between ProsFit and Forward AM now looks set to raise their quality of life.

Innovating with Exoskeleton Orthotics for Spinal Cord Injury
Discover how a team from Delft University of Technology 3D prints an exoskeleton with Forward AM's filaments.

How Additive Manufacturing Lends a Helping Hand
Read about how the Victoria Hand Project makes highly functional prosthetic devices possible for developing countries - 3D printed on-site and on-demand with Forward AM’s filament Ultrafuse® PLA, and with the help of a dedicated network of clinicians.
Download our 2023 Orthotics & Prosthetics Brochure
3D Printing Materials Recommendations for O&P


Photopolymers
Our Ultracur3D® photopolymers are based on BASF‘s decades of experience in polyurethane research and production. Benefit from the broad range of advanced photopolymer resins for footwear applications.
Ultracur3D® ST 45
Multi-Purpose Resin with Optimum Toughness and Processing Speed
Ultracur3D® ST 80
Multi-Purpose Resin Targeting the Lowest Cost per Part
Ultracur3D® ST 1400
Multi-Purpose Resin with Superior Toughness and Durability
Ultracur3D® RG 35
Rigid Resin with Optimum Combination of Strength, Stiffness and Temperature Resistance
Ultracur3D® EL 60
Flexible Resin with Quick Elastic Response and Low Hardness (Shore 75 A)

Powders
Our Ultrasint® polymer powders set new standards in Additive Manufacturing for the footwear industry as they enable various applications flexibility, elasticity and excellent processability.
Ultrasint® TPU01
Thermoplastic Polyurethane Powder for HP Jet Fusion Printers
Ultrasint® TPU 88A
Thermoplastic Polyurethane Powder for durable parts with excellent flexibility
Ultrasint® PA11
Bio-Derived PA11 Powder for Durable Parts with Exceptionally High Toughness
Ultrasint® PP 1400 Black
Advanced Polypropylene Powder for a Wide Range of Innovative Applications
HP 3D High Reusability PP enabled by BASF
Fully functional polypropylene for use on HP JF5200 series printers

Filaments
Our experts for Fused Filament Fabrication (FFF) provide you with an extensive range of materials offering a variety of beneficial material properties such as ease of print, dimensional stability, durability, and flexibility.
Ultrafuse® PP
Ultrafuse PP is high-performance thermoplastic with low density, high elasticity and high resistance to fatigue.
Ultrafuse® PLA PRO1
Speed, Strength, Versatility and Consistency
Ultrafuse® TPU 64D
The hardest elastomer in BASF Forward AM’s flexible product line
Ultrafuse® TPU 85A & TPU 90A & TPU 95A
Flexible BASF Filament Based on Elastollan® with outstanding non-slip soft touch and abrasion resistance
Ultrafuse® PPSU
For High Temperature Stable Applications
Real-Life Appplications
Discover real life projects and find out more about Additive Manufacturing for the O&P industry in our use cases.
Webinars &Whitepapers
3D Printing Accuracy of Ultracur3D® DM 2505
With Additive Manufacturing, dental models can now be manufactured at high speed and reasonably low cost with unprecedented level of accuracy. In this study, the printing accuracy of our resin Ultracur3D® DM 2505 on the 3D dental printer Organical® 3D Print X1S from Organical CAD/CAM is being examined.
Navigating 3D Printing for the Healthcare Industry
Read our whitepaper to discover more about certifications and regulatory considerations for healthcare applications, 3D printing design workflow for the healthcare industry, material selection for additive manufacturing healthcare projects and real-life use cases.
3D Printing in Orthopedics
In this webinar we’re hosting together with the medtech company Spentys, we will provide a practical framework that helps you choosing the ideal material for different orthopedic applications.
Forward AM Solutions
With our expertise in Additive Manufacturing and chemical technologies, we offer orthopedists a bespoke solution through all steps along the whole 3D printing process – from simulation and design to printing and post-processing.
Our experts are here to unlock the full potential of Additive Manufacturing for a vast array of medical devices.

Virtual Engineering
Lattice structures hold tremendous potential for a variety of devices in O&P. Our experts identify and design the optimal lattice structure for each project, cutting development time and cost by minimizing iterations.

Lattice Design
3D-printed lattices are repeated patterns comprised of a network of cells, beams, and nodes. These 3D-printed micro-architectures unlock entirely new designs that have been considered before unmakeable, leading to higher comfort, better rebound, aeration, and reduced weight.

Printing Service
We are here to support O&P professionals with a comprehensive end-to-end solution for their Additive Manufacturing production environment. Our trusted partners guarantee high-quality printed parts – complemented by various post-processing methods to achieve the desired surface finish.