Digital transformation of prosthetic & orthotic manufacturing - ON-1242

Project type: Innovation
Desired discipline(s): Engineering - biomedical, Engineering, Engineering - mechanical, Engineering - other
Company: Nipissing Orthopaedic Lab Inc.
Project Length: 4 to 6 months
Preferred start date: As soon as possible.
Language requirement: English
Location(s): North Bay, ON, Canada
No. of positions: 1
Desired education level: CollegeUndergraduate/BachelorMaster'sPhDPostdoctoral fellowRecent graduate
Open to applicants registered at an institution outside of Canada: No

About the company: 

Nipissing Orthopaedic Lab Inc. (NOLI) is a prosthetic and orthotic clinical and manufacturing facility based in North Bay, Ontario, serving patients throughout Northeastern Ontario. NOLI designs, manufactures, fits, and services custom prosthetic limbs, orthotic devices, and specialized footwear for patients of all ages.

Our multidisciplinary team of Certified Prosthetists/Orthotists and skilled technicians works collaboratively under one roof, allowing custom devices to be designed, manufactured, fitted, and modified locally. NOLI works closely with physicians, physiotherapists, occupational therapists, nurses, and other healthcare providers to improve mobility, function, independence, and quality of life.

NOLI is currently modernizing its traditional manufacturing processes through the adoption of digital technologies including 3D scanning, computer-aided design and modification, and additive manufacturing. Our goal is to develop practical digital workflows that complement the expertise of our clinicians and technicians while improving manufacturing efficiency, consistency, scalability, and access to specialized prosthetic and orthotic care in Northern Ontario.

Describe the project.: 

We are working to modernize the design and manufacturing of custom prosthetic and orthotic devices through the integration of 3D scanning, digital design, and additive manufacturing. This project will build upon preliminary work completed through a summer Engineering Coop project, which focused on researching available technologies and establishing the foundation for a digital manufacturing workflow.

The next phase will focus on developing, testing, and optimizing these technologies for practical use within our clinical and manufacturing environment. The candidate will work with clinicians, technicians and other manufacturing partners to identify appropriate prosthetic and orthotic applications for digital manufacturing and develop workflows that integrate 3D scanning, digital modification/design, and 3D printing with existing clinical and fabrication processes.

The candidate will conduct iterative testing of digital workflows, printing techniques, materials, design parameters, and manufacturing methods. Digitally produced models, components, and/or devices will be evaluated for factors such as accuracy, repeatability, manufacturing time, material use, cost, and suitability for clinical application. Where appropriate, results will be compared with our traditional manufacturing methods to identify opportunities, limitations, and areas requiring further development.

The project will ultimately establish standardized and reproducible digital manufacturing processes that can be incorporated into NOLI's operations. By developing and validating these workflows in a
real-world prosthetic and orthotic setting, NOLI aims to improve manufacturing efficiency and consistency, expand its technical capabilities, and increase its capacity to provide highly customized prosthetic and orthotic care to patients throughout Northern Ontario.

Required expertise/skills: 

The ideal candidate will have a background in biomedical, mechanical, or a related engineering discipline, with an interest in additive manufacturing, digital design, and healthcare applications.

Desired skills and experience include:

● 3D modelling and computer-aided design (CAD)
● Additive manufacturing and 3D printing
● 3D scanning and processing of scan data
● Experience with CAD and mesh-modelling software
● Knowledge of 3D printing materials, manufacturing parameters, and design for additive manufacturing
● Prototyping, iterative design, testing, and technical problem-solving
● Data collection, analysis, and comparison of manufacturing processes
● Development and documentation of standardized technical workflows
● Ability to work collaboratively with clinicians and technicians to translate clinical and functional requirements into practical design solutions

Experience with software such as Autodesk Fusion, Meshmixer, Nomad, Blender, or similar CAD/mesh-modelling platforms would be an asset. Experience with large-format or FDM 3D printing, biomedical applications, medical device design, orthotics/prosthetics, biomechanics, or human anatomy would also be considered an asset.

● The candidate should be comfortable independently researching technical challenges, designing and conducting structured experiments, analyzing results, and using findings to iteratively improve digital manufacturing processes.