{"id":9283,"date":"2026-01-09T08:48:21","date_gmt":"2026-01-09T07:48:21","guid":{"rendered":"https:\/\/prototal.info\/cases\/digital-prosthetics-manufacturing-with-industrial-3d-printing\/"},"modified":"2026-05-18T17:38:44","modified_gmt":"2026-05-18T15:38:44","slug":"sahva","status":"publish","type":"case_studies","link":"https:\/\/prototal.info\/uk\/cases\/sahva\/","title":{"rendered":"Digital Prosthetics Manufacturing with Industrial 3D Printing"},"content":{"rendered":"\n<p><a href=\"https:\/\/prototal.info\/uk\/services\/industrial-3d-printing\/\">Industrial 3D printing<\/a> enables faster, patient-specific orthotic solutions \u2014 without compromising craftsmanship or quality.<\/p>\n\n<p>For decades,\u00a0<a href=\"https:\/\/www.sahva.dk\/private\/proteser\/\">Sahva<\/a>\u00a0has developed and manufactured highly customized prosthetic and orthotic solutions, helping patients regain mobility and improve quality of life. Producing approximately\u00a01,000 prostheses annually, Sahva operates in a field where\u00a0no two products are alike\u00a0and traditional mass production is impossible.<\/p>\n\n<p>To accelerate production while maintaining the highest standards of comfort and precision, Sahva partnered with <a href=\"https:\/\/prototal.info\/uk\/about-us\/locations\/denmark\/\">Prototal&#8217;s facility in Denmark<\/a> to integrate Industrial 3D Printing into its digital workflow.<\/p>\n\n<h3 class=\"wp-block-heading\">The Challenge<\/h3>\n\n<p>Prosthetics manufacturing is rooted in craftsmanship and individual adaptation:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Every prosthesis is tailor-made to the patient<\/li>\n\n\n\n<li>Tight tolerances are critical for comfort and function<\/li>\n\n\n\n<li>Traditional methods involve manual measurement, plaster casting, and lengthy production times<\/li>\n\n\n\n<li>Fast delivery is essential to restore mobility and quality of life<\/li>\n<\/ul>\n\n<p>Sahva sought a solution that could shorten lead times, increase capacity, and support digitalisation \u2014 without compromising quality or clinical standards.<\/p>\n\n<h3 class=\"wp-block-heading\">The Solution: From Craft to Digital Workflow<\/h3>\n\n<p>Together with Prototal, Sahva replaced parts of the traditional process with a fully digital, additive manufacturing workflow:<\/p>\n\n<h4 class=\"wp-block-heading\"><strong>Traditional process<\/strong><\/h4>\n\n<ul class=\"wp-block-list\">\n<li>Consultation<\/li>\n\n\n\n<li>Measurement and plaster casting<\/li>\n\n\n\n<li>Manual production of prosthetic sockets<\/li>\n<\/ul>\n\n<h4 class=\"wp-block-heading\"><strong>New digital process<\/strong><\/h4>\n\n<ul class=\"wp-block-list\">\n<li>Consultation<\/li>\n\n\n\n<li>3D scanning<\/li>\n\n\n\n<li>CAD modelling<\/li>\n\n\n\n<li>Industrial 3D printing<\/li>\n<\/ul>\n\n<p>This approach preserves the principles of craftsmanship while enabling faster, more consistent, and scalable production.<\/p>\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p><em>\u201cIt 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.\u201d<\/em><br \/><strong>\u2013 Frederik Ahlers Gislason, Project Manager, Sahva<\/strong><\/p>\n<\/blockquote>\n\n<h3 class=\"wp-block-heading\">Manufacturing at Scale with Precision<\/h3>\n\n<p>Today, 200 of Sahva\u2019s approximately 1,000 annual prostheses are 3D printed in collaboration with Prototal.<\/p>\n\n<p>The process follows a clear structure:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Orthotists across Sahva\u2019s nationwide clinics use mobile 3D scanners<\/li>\n\n\n\n<li>Patient data is transferred digitally and securely<\/li>\n\n\n\n<li>Print-ready designs are sent to Prototal<\/li>\n\n\n\n<li>Finished 3D-printed sockets are delivered directly to clinics<\/li>\n<\/ul>\n\n<p>This streamlined process:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Reduces manual handling<\/li>\n\n\n\n<li>Increases productivity<\/li>\n\n\n\n<li>Improves capacity without adding complexity<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\">Certified Quality for Medical Applications<\/h3>\n\n<p>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.<\/p>\n\n<p><\/p><h3 data-start=\"3018\" data-end=\"3066\" style=\"white-space: normal\"><\/h3><p data-start=\"3287\" data-end=\"3314\" style=\"white-space: normal\">This certification ensures:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Proven mechanical strength<\/li>\n\n\n\n<li>Consistent quality<\/li>\n\n\n\n<li>Patient safety and confidence<\/li>\n<\/ul>\n\n<p><span style=\"font-size: revert;white-space: normal;font-family: var(--wp--preset--font-family----wp--preset--font-family--roboto)\">Prototal\u2019s experience in <\/span>medical-grade Industrial 3D Printing<span style=\"font-size: revert;white-space: normal;font-family: var(--wp--preset--font-family----wp--preset--font-family--roboto)\"> is critical in meeting these stringent requirements.<\/span><\/p>\n\n<h3 class=\"wp-block-heading\">Tailor-Made Prosthetics with Advanced Design Freedom<\/h3>\n\n<p>Industrial 3D Printing enables a level of customisation that traditional manufacturing cannot match:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Patient-specific geometry<\/li>\n\n\n\n<li>Integrated technical features<\/li>\n\n\n\n<li>Space for batteries, electronics, and specialised components<\/li>\n\n\n\n<li>Continuous design optimisation through CAD<\/li>\n<\/ul>\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p><em>\u201cPrototal adds significant value to our solutions. Faster turnaround, customised designs, and high technical quality directly improve patients\u2019 everyday lives.\u201d<\/em><br \/><strong>\u2013 Frederik Ahlers Gislason, Sahva<\/strong><\/p>\n<\/blockquote>\n\n<h3 class=\"wp-block-heading\">Results &amp; Business Impact<\/h3>\n\n<p>The collaboration delivers clear benefits:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>Shorter lead times from assessment to finished prosthesis<\/li>\n\n\n\n<li>Higher capacity without compromising quality<\/li>\n\n\n\n<li>Digitally scalable production<\/li>\n\n\n\n<li>Improved patient outcomes and comfort<\/li>\n\n\n\n<li>New opportunities for innovation and market expansion<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\">Enabling the Future of Orthotics<\/h3>\n\n<p>Industrial 3D Printing supports healthcare providers in combining craftsmanship, digitalisation, and scalability.<\/p>\n\n<p>At Prototal, we help medical and orthotics companies transform complex, patient-specific requirements into certified, production-ready solutions \u2014 faster and with confidence.<\/p>\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Industrial 3D printing enables faster, patient-specific orthotic solutions \u2014 without compromising craftsmanship or quality. For decades,\u00a0Sahva\u00a0has developed and manufactured highly customized prosthetic and orthotic solutions, helping patients regain mobility and improve quality of life. Producing approximately\u00a01,000 prostheses annually, Sahva operates in a field where\u00a0no two products are alike\u00a0and traditional mass production is impossible. To accelerate [&hellip;]<\/p>\n","protected":false},"author":3,"featured_media":19510,"comment_status":"open","ping_status":"closed","template":"","categories":[95,229],"class_list":["post-9283","case_studies","type-case_studies","status-publish","has-post-thumbnail","hentry","category-industrial-3d-printing","category-orthotics-prosthetics-applications"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Digital Prosthetics Manufacturing with Industrial 3D Printing | Prototal<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/prototal.info\/uk\/cases\/sahva\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Digital Prosthetics Manufacturing with Industrial 3D Printing | Prototal\" \/>\n<meta property=\"og:description\" content=\"Industrial 3D printing enables faster, patient-specific orthotic solutions \u2014 without compromising craftsmanship or quality. For decades,\u00a0Sahva\u00a0has developed and manufactured highly customized prosthetic and orthotic solutions, helping patients regain mobility and improve quality of life. Producing approximately\u00a01,000 prostheses annually, Sahva operates in a field where\u00a0no two products are alike\u00a0and traditional mass production is impossible. 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