Vat-Photopolymerised Materials for Custom Orthoses and Prosthetic Interfaces: Device Mechanics, Workflow Qualification and Evidence Boundaries
Segurola, Juan
2026-08-27 · Report · Version 1.1
Patient-specific additive manufacturing can integrate scanning, digital design and customised geometry into orthotic and prosthetic workflows. For vat photopolymerisation, the strongest direct evidence currently concerns customised wrist-hand orthoses, including DLP printability studies, clinical workflow comparisons and shape-memory 4D orthosis demonstrations. Evidence for load-bearing prosthetic sockets is broader in additive manufacturing but is not yet sufficient to infer equivalent performance for VPP materials. This review separates four material roles - structural orthotic shell, compliant interface, adaptive/4D element and load-bearing prosthetic component - and maps each to geometry, mechanical durability, environmental conditioning, finished-article biological evaluation and workflow controls. ISO 22523:2006 is used as the general external prosthesis/orthosis requirements reference, ISO 10328:2016 is restricted to its lower-limb structural-testing scope, and ISO 10993-1:2025 is used only for biological evaluation within risk management. 3Dresyns material families are presented as implementation profiles, not as approved medical- device materials.