nils sorger’s elbow brace fuses 3D printing and laser cutting

+/- brace is customizable based on each user’s data

Showcased at Isola Design during Milan Design Week, +/- Brace is a user-centered, fully customizable elbow brace that is produced by combining additive 3D printing and subtractive laser cutting technology. Designed by Nils Sorger during an internship at WertelOberfell, the brace is pain relieving, promoting comfort and reducing the risk of injury or irritation during demanding physical tasks or sport activities. Taking the user’s data and existing users’ measurements into account, the scripted algorithm calculates the optimal design for each individual’s personalised +/- Brace. The user could then either fabricate the brace on their own, order it within the maker community, or proceed with purchasing it on the platform. Users can also easily customize size, form, structure, and padding via the accompanying app.

image by Jana Gautier

nils sorger adopts a user-centered approach

Nils Sorger’s +/- Brace resolves the challenge with conventional medical products which are either unaffordable or non-individualized by enhancing efficiency in 3D printed fabric-based manufacturing and embracing an open source process. Utilizing Grasshopper with a custom built script, the designer inputted body measurements as parameters to generate data output for our FDM printer and the laser cutter, which enabled a user-centered, generative exploration, and a responsive design approach aligned with open-source principles. Combining 3D printing and laser cutting in one device, complex shapes and structures can be produced that would be difficult to realize with conventional manufacturing methods.

highly integrated elbow braces created in cooperation with WertelOberfell | image by Nils Sorger

utilizing open-source technology

To find the optimal breathable and flexible pattern, many different iterations that were generated using Nils Sorger’s grasshopper scripts were laser-cut and evaluated. In search of the best suited material, over 70 different fabric types were tested, and to achieve the best cutting results, to improve precision and to reduce waste, all laser-cutting settings needed to be optimised. The chosen 4-way stretch softshell fabric, composed of 49% Polyester, 30% Polyamide, 12% Polyurethane, and 9% Elasthan, weighing 380 g/m2, offers multiple benefits for an elbow brace. It provides a comfortable and flexible fit and ensures unrestricted movement while offering excellent support and stability to the elbow joint. Its fibre composition makes it durable and breathable, and therefore an ideal choice for everyday sports and injury rehabilitation. A range of FDM-printed pads were developed and iterated, utilizing TPU filament with a shore hardness of 98A. Using a TPMS Gyroid gradient structure as an infill, the final product has characteristics of materials like foam or gel.

Finding the optimal fit was about balancing various fabric properties with the corresponding cutting algorithm. This and performance driven project led to the development of a new production process and resulted in a unique product aesthetic, paving the way for a range of new products. Improving and enhancing efficiency in 3D printed fabric-based manufacturing and embracing an open source process ultimately resulted in the creation of affordable individualized braces for people in need of them.

customizability, 3D printing, and laser cutting allows on-demand production | image by Jana Gautier

the pain relieving +/- Brace promotes comfort and reduces the risk of injury | image by Jana Gautier

image by Jana Gautier

over 70 fabric types were tested to find the best material | image by Nils Sorger

the chosen 4-way stretch softshell fabric offers multiple benefits for an elbow brace | image by Nils Sorger

various FDM-printed pads were created with TPU filament 98A | image by Nils Sorger

balancing various fabric properties with the corresponding cutting algorithm | image by Nils Sorger

the +/- Brace app allows users to customize size, form, and structure based on their data and existing measurements

project info:

name: +/- Brace
designer: Nils Sorger / in cooperation with WertelOberfell

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edited by: ravail khan | designboom