Metal Rapid Prototyping for Rehabilitation Devices

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Metal Rapid Prototyping for Rehabilitation Devices

Metal Rapid Prototyping for Rehabilitation Devices

Material:Aluminum

Finish:As-Printed / Raw Finish

Description

This lightweight metal bracket is produced using precision DMLS/SLM 3D printing technology and engineered for use in exoskeletons and rehabilitation devices. Built for strength, accuracy, and ergonomic performance, it enables complex geometries that traditional machining cannot replicate. Ideal for wearable assistive systems, it delivers an exceptional strength-to-weight ratio, a custom anatomical fit, and integrated mounting features for sensors and actuators.

Manufactured under ISO 9001:2015 and ISO 13485:2016 quality systems, this component meets the high standards required for medical and industrial rehabilitation equipment.

Looking for a custom bracket solution for your wearable or rehab device? Contact us to discuss your project or request a quote today.

Process

DMLS (Direct Metal Laser Sintering) and SLM (Selective Laser Melting) are advanced metal 3D printing processes used to produce complex, high-performance parts directly from CAD data—without traditional tooling. These technologies are ideal for lightweight brackets in wearable exoskeletons, rehab robotics, and orthopedic assistive devices, where strength, weight reduction, and custom geometry are critical.

Material Selection & Design Optimization	Common alloys: Titanium (Ti6Al4V) – biocompatible, lightweight, corrosion-resistant Aluminum (AlSi10Mg) – excellent strength-to-weight ratio Stainless Steel (316L) – wear-resistant, sterilization-ready Design is tailored for lightweighting using lattice structures, internal channels, or topology optimization
File Preparation & Build Setup	CAD files (STEP, STL) are validated and sliced into ultra-thin layers (20–60 microns) Build orientation, support strategy, and heat stress simulation are finalized to optimize structural integrity and material use
DMLS / SLM 3D Printing	A high-power fiber laser selectively fuses metal powder layer by layer inside a nitrogen- or argon-filled chamber Printing is done on a metal build plate, with real-time monitoring for temperature, energy input, and melt pool stability
Cooling & Powder Recovery	After printing, the part cools in the chamber to minimize warping Unfused powder is removed and recycled for future builds
Support Removal & Post-Processing	Supports are removed manually or via CNC machining Part undergoes finishing operations, such as: Heat treatment (stress relieving or HIP—hot isostatic pressing) Surface polishing, blasting, or shot peening Precision CNC machining of mating surfaces, threads, or bores
Inspection & Quality Control	Dimensional inspection via CMM or 3D scanning Mechanical testing if required (tensile, fatigue) Surface roughness and porosity analysis Documentation for ISO 13485

Applications

For Exoskeletons & Rehabilitation Devices

Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLM) are ideal for producing custom, high-strength, and lightweight metal brackets used in next-generation wearable assistive technologies. These parts offer superior mechanical properties, complex geometry support, and biocompatibility—making them a perfect fit for advanced rehabilitation and mobility systems.

Industry	Application Examples
Structural Connectors in Wearable Exoskeleton Frames	Load-bearing brackets that connect hip, knee, or spine modules Designed to support dynamic motion while remaining lightweight for all-day wear
Motor and Sensor Mounting Brackets	Precision mounts for electric actuators, torque sensors, and rotary encoders Integrated cable routing channels and mounting bosses
Adjustable Joint Housings and Pivot Supports	Custom articulating joints for ankle, knee, or shoulder modules Designed for high-cycle fatigue and ergonomic motion paths
Patient-Specific Fitting Fixtures	Brackets contoured to fit individual anatomy (e.g., thigh, calf, or torso) Lightweight titanium frames with smooth contours for comfort and safety
Rehabilitation Robotics Subframes	Load-distribution brackets for seated rehab exoskeletons and physiotherapy machines Internal voids or channels for airflow, weight savings, or sensor wiring
Gait Training and Lower-Limb Assist Devices	Structural links and mounting blocks for powered orthoses and robotic gait trainers Designed to sustain real-world motion forces during therapy or mobility assistance
Upper-Limb Assist Systems	Compact brackets for shoulder, elbow, or wrist actuated support systems Includes joints, cable guide mounts, and end-effector support frames

Specifications

Part number: RY-H0202

Materials Available: Plastic, Stainless Steel, Steel, Aluminum, etc.

Tolerance: ±0.05mm

Material Certificates: Available

MOQ:1 piece

Drawing Accepted: PRO/E, Auto CAD, SolidWorks, UG, CAD / CAM / CAE, PDF

RoHS/REACH Report: Available

Certificate: ISO9001:2015, ISO13485:2016

Non-disclosure agreement: Strictly sign a confidentiality agreement NDA to give you peace of mind.

Other CNC Parts

Email Us: mitani@rymachining.com

FAQ

What materials are used for this 3D printed metal bracket?

We typically use high-strength materials such as Titanium (Ti6Al4V), Aluminum (AlSi10Mg), or Stainless Steel (316L, 17-4PH)—selected based on the required strength, weight, and biocompatibility for medical or industrial applications.

Is this bracket suitable for wearable medical devices?

Yes. It is engineered for wearable exoskeletons and rehabilitation systems, offering a lightweight structure, ergonomic contours, and optional biocompatible materials compliant with ISO 13485 standards.

Can the bracket support integrated components like sensors or actuators?

Absolutely. The design includes mounting features and customizable geometries to integrate sensors, actuators, control modules, or mechanical joints—ideal for robotic rehab and motion-assist systems.

What is the maximum build size or customization available?

We support fully custom geometries with build sizes up to 300mm x 300mm x 300mm, depending on material. We also offer topology optimization and co-design support for application-specific needs.

How durable is the bracket under repeated stress and motion?

DMLS/SLM parts offer excellent fatigue resistance and structural integrity. With proper post-processing (e.g., heat treatment), these brackets withstand repetitive motion, impact, and long-term use in dynamic environments.

Outstanding Achievements and Partnerships

We take pride in our outstanding achievements and strong partnerships. Our commitment to great communication, service, and integrity has led to excellent results.

Join us as a valued partner, and together, we can make a positive impact on CNC.

Metal Rapid Prototyping for Rehabilitation Devices - Rollyu

Metal Rapid Prototyping for Rehabilitation Devices

Other CNC Parts

Email Us: mitani@rymachining.com

FAQ

Outstanding Achievements and Partnerships

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