Case Study: iOrthotics × HP Multi Jet Fusion — Additive Manufacturing at Scale

iOrthotics × HP: An Official Multi Jet Fusion Case Study

iOrthotics is an official HP case-study partner for additive manufacturing — recognised globally for adopting HP's Multi Jet Fusion (MJF) 3D printing to transform how custom foot orthoses are designed, produced and scaled.

From subtractive to additive

iOrthotics became the first commercial customer in Australia to purchase an HP Jet Fusion 3D 4200 Printing Solution. The shift away from traditional polypropylene milling made iOrthotics one of the first orthotic manufacturers in the world to fully transition from subtractive milling to additive manufacturing.

“The extensive research and testing we conducted with the University of Queensland provided the empirical evidence that devices manufactured by HP's Multi Jet Fusion 3D printing technology are 40-60% stronger than those produced using traditional polypropylene milling.” — Dean Hartley, Founding Director & General Manager, iOrthotics

Sustainability impact

Subtractive milling previously wasted ~95% of the polypropylene used in production. HP's Multi Jet Fusion technology reduced material waste to less than one percent — underpinning iOrthotics' near-zero-waste EnviroFoam manufacturing.

Scalability & speed

Output leapt from around 30 plastic devices per day (via subtractive milling) to more than 90 per day — a fourfold productivity increase — enabling iOrthotics to service the growing Australian podiatry market and expand into orthotic, prosthetic and industrial 3D bureau printing.

Read the full case study on the official HP site.