How are fairings made? Typically, medical device manufacturers have a one-size-fits-all mentality. They start with a product and end with the user, whereas we start with the user and end with the product. We believe that if you're going to create something that will be an intimate part of someone's body and outward expression, then that's really the only way to do it. Here's how it works:
Scan. We use image-based 3D scanning technology to capture images of both the "sound side" leg and the prosthetic leg in under a minute. A 3D computer model results, and a mirrored "sound side" leg is then superimposed over the prosthetic leg. This way, the wearer is given their body symmetry back, at least to the greatest degree possible. Bilateral amputees can find a "stand-in" who approximates their original or preferred shape. We can help customers find a stand-in if assistance is needed.
Design. Once the scanning process is complete, the customization of the Fairing is directed by the user. He or she may select from an array of form templates, patterns, tattoos, materials, metal plating, graphics—whatever it takes to make the end-product entirely and absolutely personalized, and personal to them. We developed an online tool called the "Configurator" which allows users to explore and apply a range of design styles to see how the end-result might appear (coming in July). Although there are quite a few options from which to choose, we are always looking to build on the range of materials, finishes, patterns, and graphics we offer. If you have a suggestion, please let us know.
Print. The advent of 3D printing has allowed us to build something based on the unique shape of a particular user, modify it with our designs, and turn it into something physical that can be worn. The resulting products are flexible, durable, and lightweight. Watch the video to get a general sense for just how physical parts are created from digital models.