Industrial 3D printing enables faster, patient-specific orthotic solutions — without compromising craftsmanship or quality.
For decades, Sahva has developed and manufactured highly customized prosthetic and orthotic solutions, helping patients regain mobility and improve quality of life. Producing approximately 1,000 prostheses annually, Sahva operates in a field where no two products are alike and traditional mass production is impossible.
To accelerate production while maintaining the highest standards of comfort and precision, Sahva partnered with Prototal’s facility in Denmark to integrate Industrial 3D Printing into its digital workflow.
The Challenge
Prosthetics manufacturing is rooted in craftsmanship and individual adaptation:
- Every prosthesis is tailor-made to the patient
- Tight tolerances are critical for comfort and function
- Traditional methods involve manual measurement, plaster casting, and lengthy production times
- Fast delivery is essential to restore mobility and quality of life
Sahva sought a solution that could shorten lead times, increase capacity, and support digitalization — without compromising quality or clinical standards.
The Solution: From Craft to Digital Workflow
Together with Prototal, Sahva replaced parts of the traditional process with a fully digital, additive manufacturing workflow:
Traditional process
- Consultation
- Measurement and plaster casting
- Manual production of prosthetic sockets
New digital process
- Consultation
- 3D scanning
- CAD modelling
- Industrial 3D printing
This approach preserves the principles of craftsmanship while enabling faster, more consistent, and scalable production.
“It only takes a few days for Prototal to deliver a high-quality solution. Their flexibility and technical expertise are key reasons why we have relied on them already for several years.”
– Frederik Ahlers Gislason, Project Manager, Sahva
Manufacturing at Scale with Precision
Today, 200 of Sahva’s approximately 1,000 annual prostheses are 3D printed in collaboration with Prototal.
The process follows a clear structure:
- Orthotists across Sahva’s nationwide clinics use mobile 3D scanners
- Patient data is transferred digitally and securely
- Print-ready designs are sent to Prototal
- Finished 3D-printed sockets are delivered directly to clinics
This streamlined process:
- Reduces manual handling
- Increases productivity
- Improves capacity without adding complexity
Certified Quality for Medical Applications
As a unique provider on the market, Shava offers 3D-printed prosthetic sockets tested and approved according to DS/EN ISO 10328:2016, the international standard for structural testing of lower-limb prostheses.
This certification ensures:
- Proven mechanical strength
- Consistent quality
- Patient safety and confidence
Prototal’s experience in medical-grade Industrial 3D Printing is critical in meeting these stringent requirements.
Tailor-Made Prosthetics with Advanced Design Freedom
Industrial 3D Printing enables a level of customization that traditional manufacturing cannot match:
- Patient-specific geometry
- Integrated technical features
- Space for batteries, electronics, and specialised components
- Continuous design optimisation through CAD
“Prototal adds significant value to our solutions. Faster turnaround, customised designs, and high technical quality directly improve patients’ everyday lives.”
– Frederik Ahlers Gislason, Sahva
Results & Business Impact
The collaboration delivers clear benefits:
- Shorter lead times from assessment to finished prosthesis
- Higher capacity without compromising quality
- Digitally scalable production
- Improved patient outcomes and comfort
- New opportunities for innovation and market expansion
Enabling the Future of Orthotics
Industrial 3D Printing supports healthcare providers in combining craftsmanship, digitalization, and scalability.
At Prototal, we help medical and orthotics companies transform complex, patient-specific requirements into certified, production-ready solutions — faster and with confidence.
