Leg&airy: Pioneering Custom Orthotics with Advanced 3D Printing and AI for Enhanced Mobility

For countless individuals worldwide, particularly those with reduced mobility, daily life presents a unique set of formidable challenges. Their journey often involves a long, arduous path marked by frequent medical appointments, unexpected setbacks, moments of profound hope, and, at times, disheartening disappointment. Navigating this landscape requires immense resilience. It was with a profound understanding of these struggles that Leg&airy – Orthopedic Wonders, a visionary company headquartered in Baar, Switzerland, was founded. Their unwavering mission is to provide unparalleled support to these patients, with a special focus on empowering children, helping them to not only regain but significantly enhance their mobility. Through the innovative application of individually adapted orthoses, Leg&airy ensures that each patient benefits from a truly personalized and responsive follow-up experience. This approach allows Leg&airy to forge a sensitive and deeply therapeutic path, offering everyone the promise of lifelong support through a potent combination of modern service delivery, intelligent technology integration, and exquisitely tailor-made designs. To bring this ambitious vision to life, Leg&airy strategically leverages cutting-edge advancements, most notably in the fields of 3D printing and artificial intelligence. The company aims not just to provide devices, but to empower its customers to strengthen their personal resilience, ultimately transforming them into true masters – or even “legends” – in overcoming their physical challenges. We recently had the distinct pleasure of meeting with Leg&airy’s CEO, Faizan Mohammad, to delve deeper into their groundbreaking work and discover the future they are shaping.

3DN: Could you introduce yourself and tell us how Leg&airy was created?

My name is Faizan Mohammad, and I am the CEO and co-founder of Leg&airy. Before embarking on the journey to establish Leg&airy, I cultivated extensive and valuable experience as an IT specialist and business consultant across diverse sectors, including healthcare, pharmaceuticals, and finance. This background provided me with a unique blend of technical acumen, strategic insight, and a deep understanding of complex operational environments. However, the creation of Leg&airy transcended the realm of a mere business venture for me; it was, and remains, a project driven by a deeply personal commitment and a profound passion. The genesis of Leg&airy lies in a pivotal moment in my life: in 2018, my son received a diagnosis of a rare neuromuscular disease. This condition severely impacted his walking ability and necessitated the use of orthopedic devices. It was during this intensely challenging period that I gained firsthand insight into the protracted and often arduous process of finding and fitting a suitable prosthesis or orthosis. I witnessed the emotional toll of repeated fittings, the discomfort of ill-adapted devices, and the general lack of innovation in a field so crucial to quality of life.

This personal experience ignited a powerful realization within me: despite its critical importance, the field of fitting and manufacturing orthopedic devices had seen surprisingly little technical advancement or truly disruptive innovation over the preceding decades. Traditional methods, often involving messy plaster casts and manual adjustments, were cumbersome, time-consuming, and frequently failed to deliver optimal comfort or functionality. This stark observation became the catalyst, the driving force that compelled me to envision and then actively work towards revolutionizing the world of orthopedic devices, striving to fundamentally improve the experience for patients and their families. Our journey began in 2018, with initial experiments focused on manufacturing orthotics for dogs – an invaluable learning ground that allowed us to refine our techniques and material science. From these humble yet innovative beginnings, we have progressively expanded our product portfolio and now proudly offer comprehensive orthopedic equipment designed for various parts of the body, from head to toe. A cornerstone of our approach is the individual adaptation of each product to the unique anatomy of the individual’s body, meticulously achieved through the use of advanced 3D scanners. Beyond precision, our products are engineered to be remarkably lightweight and highly breathable, guaranteeing superior comfort for prolonged wear. Moreover, Leg&airy’s offerings distinguish themselves in the market through their commitment to modern, personalized aesthetics, transforming medical devices into empowering and visually appealing accessories.

3DN: How and why do you use 3D printing? What value does it add to the Leg&airy technology?

It’s truly an interesting genesis story! My journey into 3D printing began a few years ago when I visited a 3D printing booth at a trade show. I was instantly captivated and profoundly impressed by the sheer precision, the intricate possibilities, and the transformative potential that this technology offered. The inherent beauty and immense advantage of 3D printing lie in its unparalleled ability to allow us to create truly tailor-made, perfectly individualized solutions for each and every patient. We understand that no two feet, no two hands, and no two backs are ever exactly alike; human anatomy is wonderfully unique. While previous solutions in orthotics did offer a degree of customization, the fitting process was predominantly performed by hand. This traditional approach carried inherent risks: the potential for less accurate results, inconsistencies, and an unwavering dependency on the individual knowledge, skill, and experience of the involved technicians. This human element, while valuable, also introduced variability and limitations in precision. With 3D printing, we possess the power to fundamentally alter this paradigm.

Thanks to the strategic integration of the most advanced 3D printing and scanning technology, meticulously combined with our proprietary and unique Leg&airy Design fitting process, we can now perfectly adapt each product to the precise contours and specific needs of the customer’s body. This level of anatomical precision and personalized fit is simply unattainable with any other conventional manufacturing process. The result is not just a better orthosis, but a device that feels like a natural extension of the body, offering unprecedented comfort and functionality. By leveraging these advanced additive manufacturing techniques, we have successfully managed to set a revolutionary new benchmark in wearing comfort, significantly enhancing the quality of life for our users. Our 3D scanning technology captures an exact digital replica of the affected body part, eliminating the inaccuracies of traditional plaster casting. This digital data is then fed into our sophisticated design software, where our specialized Leg&airy Design process refines the orthosis model, optimizing its structure for strength, breathability, and ergonomic comfort. Finally, 3D printing brings this digital design to life with incredible accuracy, layer by layer, creating a device that fits flawlessly, reduces pressure points, and promotes natural movement. This integrated approach ensures that every Leg&airy orthosis is not just custom-made, but custom-optimized.

3DN: What materials and technologies do you use?

To consistently ensure the exceptional fit, unparalleled precision, and superior performance of our products, Leg&airy employs a strategic combination of advanced additive manufacturing technologies. Specifically, we primarily utilize the Selective Laser Sintering (SLS) printing process, alongside FDM (Fused Deposition Modeling) printing technology for certain applications. These processes are expertly paired with high-performance materials such as Thermoplastic Polyurethane (TPU) and Polyamide 12 (PA12). This carefully selected combination of technologies and materials allows us to achieve incredibly high levels of precision, boasting a print accuracy of 0.3 mm, even at a minimum wall thickness of only 1 millimeter. This meticulous precision is crucial for creating devices that are lightweight yet robust, and perfectly contoured to the user’s anatomy.

PA12, particularly its carbon-reinforced variant, stands out as our material of choice for many of our core products. This advanced polyamide not only distinguishes itself through its exceptional lightness and remarkable strength, making our orthoses durable without adding unnecessary bulk, but also by its excellent skin compatibility. This latter characteristic is paramount in medical devices that are in constant contact with the skin, minimizing the risk of irritation or allergic reactions and ensuring long-term comfort. The carbon reinforcement further enhances the material’s structural integrity and rigidity while maintaining its lightweight properties, which is vital for effective support and patient comfort. For applications requiring more flexibility, such as certain joints or softer contact points, TPU offers its unique blend of elasticity, durability, and shock absorption. We are immensely proud to not only offer groundbreaking and innovative orthopedic solutions that redefine patient care but also to uphold a strong commitment to environmental friendliness and sustainability throughout our production processes. By embracing additive manufacturing, we achieve an astounding material savings of 96% compared to traditional, subtractive manufacturing methods. This significantly reduces waste, minimizes our ecological footprint, and aligns with our vision of a responsible and forward-thinking healthcare industry.

3DN: How do you use AI for the fabrication process?

The integration of Artificial Intelligence (AI) represents the next frontier in our mission to revolutionize orthotics. Each of our orthoses is already meticulously tailored to the patient’s precise digital twin during our specialized Leg&airy design process. This digital twin is a highly accurate virtual model of the patient’s anatomy, generated from detailed 3D scan data. Building upon this foundation, we are currently engaged in a pioneering research project, in close collaboration with leading universities, focused on developing an intelligent machine learning algorithm. The ambitious goal of this algorithm is to facilitate the fully automatic adaptation of orthopedic products to patients during the fitting stage. This endeavor presents a particular, yet exciting, challenge, precisely because every person is inherently unique. The anatomical differences between a child and an adult, or between individuals of varying sizes and body types, are profound and require an incredibly sophisticated system to account for them.

The AI-powered manufacturing system we envision will learn from vast datasets of successful orthotic designs, patient feedback, and biomechanical analyses. It will be capable of autonomously identifying optimal design parameters, generating complex support structures, and fine-tuning the geometry of the orthosis to provide the most effective and comfortable fit. With the aid of AI-based manufacturing, our primary objective is to significantly further reduce the critical time lag between the initial patient consultation and the final delivery of the customized orthopedic products. This acceleration of the process will not only improve patient satisfaction but also enhance overall therapeutic outcomes by ensuring quicker intervention. Furthermore, by leveraging the unparalleled efficiency and scalability offered by AI, we aim to make life easier and significantly improve the well-being of an even greater number of patients globally with our state-of-the-art products in the future, democratizing access to truly personalized medical care.

3DN: What projects have you been most passionate about? What are your goals?

Without a doubt, the most exciting and deeply passionate projects were the very first prototypes we developed! We affectionately refer to these early iterations as “learning opportunities,” and for good reason. The path was certainly not without its challenges; we faced numerous hurdles, ranging from the intricate selection of appropriate materials to the optimization of complex structural designs. Each prototype presented its own set of problems, demanding creative solutions and relentless dedication. However, with every mistake made, with every “failed” attempt, we gained invaluable insights and progressively moved closer to achieving the ideal solution. Looking back today, I am profoundly grateful for each of those initial “failed attempts,” because it was precisely through these learning experiences that we forged our identity and became what we are today: Legendary. These early struggles instilled in us a deep understanding of the intricacies of orthopedic device manufacturing and solidified our commitment to continuous improvement and innovation.

Currently, we are diligently working on a multitude of new and impactful projects aimed at further advancing our mission. Our foremost priority right now revolves around the broader distribution of our innovative products and the expansion of our user and customer base. This involves not only reaching new markets but also, and perhaps most importantly, fostering extremely close collaboration with both patients and medical professionals, including doctors, therapists, and orthotists. This direct engagement is crucial; it allows us to gather invaluable feedback and insights, ensuring that we offer the most effective and supportive therapy possible. We are committed to a continuous improvement cycle, where every piece of feedback we receive from users on the ground directly informs and refines the next generation of our products, making them even more user-friendly, comfortable, and functionally superior.

Our overarching vision is nothing short of revolutionizing the global orthopedic market. We aim to achieve this by fundamentally redefining how orthotics are not only manufactured and precisely fitted but also how they are ultimately delivered and integrated into the lives of our users. At the absolute core of all our efforts is the patient; they are at the center of every design decision, every technological advancement, and every service we provide. Our unwavering focus is on creating the best possible experience for them and ensuring the unequivocal success of their treatment. Our primary, deeply personal goal is to ensure that children, in particular, not only benefit from wearing orthotics and prosthetics but genuinely enjoy the experience, enabling them to manage their daily lives in the most active, comfortable, and empowered way possible, fostering independence and confidence from a young age.

3DN: Where do you see 3D printing in the medical sector in the coming years?

I foresee an absolutely enormous and transformative potential for 3D printing within the medical sector in the coming years. The fundamental truth is that every person and every body is uniquely individual, possessing distinct anatomical features and biomechanical requirements. Traditional, mass-produced standard medical products, by their very nature, often cannot adequately account for this inherent diversity. In an era defined by rapid technological advancements and digital revolution, these conventional approaches increasingly appear outdated and insufficient. In my profound opinion, every individual should unequivocally have the right to optimal medical treatment, irrespective of whether their physical appearance conforms to societal norms or standard templates. This right to personalized, effective care is a cornerstone of modern medicine.

3D printing manufacturing makes it uniquely possible to fulfill this fundamental right. The ability to create custom-fit devices, perfectly adapted to an individual’s unique anatomy, eliminates the compromises often associated with off-the-shelf solutions. Furthermore, the landscape of materials science in 3D printing has evolved dramatically. There is already a wide and growing array of 3D printing materials that are perfectly suitable for safe and effective use both in and on the human body, meeting stringent biocompatibility standards. In recent years, we have witnessed rapid and groundbreaking developments not only in the field of biocompatible materials but also in the precision and sophistication of additive manufacturing techniques themselves. Based on these impressive advancements and the clear trajectory of innovation, I firmly believe that 3D printing will become an increasingly indispensable and pervasive technology within the medical sector over the next ten years. It will find countless new applications, ranging from highly personalized orthotics and prosthetics to custom surgical guides, anatomical models for complex surgeries, bespoke dental implants, and potentially even breakthroughs in regenerative medicine and drug delivery systems. Its ability to create complex geometries, integrate multiple functions, and offer unparalleled customization will solidify its position as a cornerstone of personalized healthcare.

3DN: Any last word for our readers?

We would like to extend our most sincere and heartfelt thanks to the engaged and forward-thinking readers of 3Dnatives. Your sustained interest in and valuable contributions to the ongoing development and advancement of 3D printing technology are truly invaluable and greatly appreciated. As Leg&airy, we are immensely proud to be an active part of this vibrant 3D printing community and to have the opportunity to vividly illustrate the enormous, life-changing potential of 3D printing through the innovative products we bring to market. Our journey is a testament to what is possible when technology, compassion, and innovation converge. We invite all your readers to discover more about Leg&airy, our mission, and our transformative solutions by clicking HERE. Join us in shaping a future where mobility is a right, not a privilege, and where every individual can become a legend in their own life’s journey.

What are your thoughts on Leg&airy’s innovative approach to orthopedic wonders? We’d love to hear from you! Please share your insights in a comment below or connect with us on our LinkedIn or Facebook pages! Furthermore, don’t miss out on the latest advancements in additive manufacturing – be sure to sign up for our free weekly Newsletter to get breaking 3D printing news delivered straight to your inbox. You can also explore all our compelling videos on our YouTube channel. Interested in delving deeper into medical and dental 3D printing news? Visit our dedicated page HERE.

*All Photo Credits: Leg&airy