Flowchart for Covid-19 Emergency Management

We are all together against Covid

Covid is spreading across the Globe and even if we read News on the Web, nobody really knows how to react to this illness. More and more people need to autoisolate at the first coughing fit and they often can’t be checked by the Doctor. What can we do in these situations? How can we know if breathing symptoms and fatigue are related to Covid?

WASP solution with HRS

WASP, in partnership with Doctor Giorgio Noera, internationally renowned Heart Surgeon of HRS (Health Research and Development SRL), has set up a Self-evaluation and Self-medication Kit that permits to manage first days of sickness and to understand when call E.R. Number.

Dr. Giorgio Noera is expert in Sanitary Emergencies thanks to his work as
Member of the Technical Scientific Committee of Military Health and of the Ministry of Defense. He is also a Professor in Distater Medicine at the Modena University.

How does it work?

Legenda that explains how to read the flowchart for Covid Self-evaluation and Self-medication

Through a scoring system, where the highest numbers are linked to the most severe symptoms, everybody can self-diagnoses the illness, the level of danger and respond with over-the-counter drugs. If the score result exceeds a certain threshold, the test suggests to call the Doctor for high suspicion of Covid Illness and If health parameters results are abnormal, the test urges to call E.R. number.

Flowchart for Covid-19 self-evaluation

Covid Flowchart for Self evaluation and self medication

This Flowchart makes possible to reduce the movement of people in the Hospital Emergency Rooms: the goal is to decrease alarmism and to avoid understimation of symptoms. In this way Hospital’s Rooms will be less overcrowded and the circulation of the Virus reduced.

Easy to use

The advices are not only about medications: the chart suggests also lifestyle tips, supplements and other ideas to control the disease. It is simple and easy to use: in a short time You can know the severity of the illness, wherever You are.

The test doesn’t replace Doctor’s recommendations, but It permits to people to quickly react to the sickness from the first day and It warns the patient if his conditions are critical and It is necessary to call the E.R. Number.

Breathing exercises

There are a lot of exercises to train the breathing, the most common is sitting with straight back, inhale deeply and then exhale slowly. Repeat the exercise each time you need to calm down your Mind or to increase your Oxygen Saturation level, that needs to stay over 94.

Yoga Videos for Deep breathing

These videos contain demonstrations to improve your deep breathing practice. They have been created by Yoga Therapy, an indipendent organization of doctors and therapists that discloses Therapeutic Yoga.


Yoga therapy

Yoga Therapy aim is to share the knowledge of Yoga, ancient discipline, used in the past to treat and heal soul and body.
They promote this alternative therapy in a scientific and medical way, and they are really open to help people in this process.


Yoga Training

Yoga Therapy also freely trains Yoga Teachers to take action in the local territory, helping people to deal with stress, strenghten their immunitary system and improve their pulmonary capacity. To do this, they use Pranayama techniques.

If you are a Yoga Teacher and you want to contact them, you can call them at number 376.0130625 or writing an email to richiesta.yogatherapy@gmail.com.


HRS Health Research and Development, organization that works in natural sciences and engineering fields

HRS, Health Research and Development works in Natural Sciences and Engineering fields.

GSL Giardino di Santa Lucia, Nursing Home and medical office

Giardino di Santa Lucia is a Nursing Home and a Medical Office.

Italian Honorary Consulate, Cancùn - Isla Mujeres - Yucatàn

Caracol 3D Mask

Caracol is calling WASP against Covid-19

CARACOL is calling WASP to product Covid 19 3D printed masks

Caracol 3D Mask

Everything happened  during the lockdown; CARACOL, a reference company in Italy for the services of Additive Manufacturing  asked  for help to WASP : 10 Delta WASP 2040 PRO and 2 Delta WASP 2040 INDUSTRIAL 3D printers must be produced in the shortest time.

Stampante 3D Delta
Delta WASP 2040 INDUSTRIAL X - stampante delta professionale

We had to act quickly and well, Milan was calling and we decided to work together to produce protective devices against Covid-19.
In a few days the 3D printers were in the CARACOL production center in Lomazzo (Milano).

The non-stop production of more than 2000 Covid 19 3D printed masks, per week, printed with hypoallergenic polymeric material and equipped with an interchangeable filter, begins.

CARACOL, through a crowdfunding campaign and the support of the community, has donated masks to the Italian Red Cross, to small Italian municipalities such as Lomazzo, Cusano Milanino, Rivoli, Lanciano, and Sorrento, and to therapeutic and treatment centers.

A victory from a cooperation point of view and in the 3D printing field which leads the attention to an essential role in the manufacture of medical equipment.

The health care emergency due to the Covid-19 has shown the strengths of 3D printing which can obviate the lack of some essential devices in record times.

Now the global market shows that  3D printing must be used for additive manufacturing like never before. This allows the relocation of some production in order to face the demand peaks. It also allows diversification of the supply chain in case of emergencies in many sectors, not only the medical one but also the Automotive and Motorsport, Aerospace and Defense, Industrial Machinery, Design and Architecture fields.

CARACOL like WASP believes in a collaborative future and in technological progress, in the evolution of digital manufacturing in order to meet the needs of humanity.

3D printed mask - MY FACE MASK

Custom 3D printed Mask

MY FACE MASK: 3D printed face Mask with a replaceable filter.

Custom 3D printed mask with replaceable filter, obtained from a 3D scan of the wearer, an open-source project released.

3d printed mask

WASP has developed a open-source process that, starting from the 3D scan of the face, allows to customize and produce a tailored mask for every user.

3d printed mask - side

The wearer can be scanned using photogrammetry with a standard smartphone camera from a distance of 1 meter. All the photos taken are then reprocessed to create a 3D mesh

Our goal was to make the 3d printed face mask perfectly ergonomic, following the facial features as a second skin, a result that we obtained using My Face Mask Blender add-on.


The materials

The material used in this video is PCL: Polycaprolactone as it can be placed in direct contact with the skin.

PCL is a biomaterial widely used in the medical field, its melting point is 100°C, it doesn't warp and there's no need for a heated chamber to print it. The printed mask can be also hand-modeled to ensure a perfect fit using hot water (around 60°).

Another material that can be used is F1 BIO FLEX TPE is a TPE 27 Shore D certified. It prints at 200 ° and the result is a more flexible object and sanitizable at the same time.

The 3D printing process

All masks are printed using Delta WASP 4070 INDUSTRIAL 4.0. This 3D printer allows you to easily use technical materials like the described above.

3d printed mask - open-source process

The idea is of a 3D printed mask that can be sanitized and used many times. The filter is located in a central front slot, where it can be replaced. 
Here an interesting research concerning filters from Cambridge University.

It only takes about an hour and a half to customize a perfect fit face mask in TPE, this reducing skin irritation and long-use related issues. Two hours with PCL filament needed.

The choice of the filter

The perfect and reusable connection between face and filter, this is what we have made available to the community with the My Face Mask project. The term "filtering" opens up a huge theme, which is closely linked to the use of the tool and to the degree of security required.

We have expanded the functions of the Blender add-on due to the popular request to support different standard filters based on your preference and the availability of materials.


My Face Mask Add-on has now been updated with a lot of new functionalities.

As requested the add-on supports now different kinds of filters from open-source projects. In this way anyone can choose what filter to use on its customized mask, depending on preferences and availability.

The filters available are five:

The cylindrical joint is designed for electrostatic medical filters, specifically designed for the filtration of viruses and bacteria. These are usually available just for hospitals and health facilities for it’s important that they have the priority for this kind of product.
The joint can be tapered for granting the best held possible on the filter.

Requires: Electrostatic medical filter

HEPAs are filtering systems with a very wide range of applications. They are based on the principle of folding for obtaining the maximum filtering surface.
One of the easiest to find is the replacement for Roomba i7, for which these joint has been designed.

Can HEPA filters capture nanoparticles?

Requires: Roomba i7 HEPA

WASP joint has been studied to be compatible with all kinds of filtering fabrics with the use of an internal frame.
The shape has been studied to have a wide area of breathing.
For the choice of the filtering fabric you can for example use the material from a N95 surgical mask or a traditional fabric, following the related studies.

Study on 30+ materials for DIY masks:

Requires: 3D printed frame DOWNLOAD, fabric

Montana joint borns from a popular US project for using a single N95 mask to produce 6 filters.

Montana masks project:

Requires: 3D printed frame DOWNLOAD, N95 mask

The circular adapter allows fixing fabrics without the necessity of a frame by using an elastic element.
For the choice of the filtering fabric you can for example use the material from a N95 surgical mask or a traditional fabric, following the related studies.

Study on 30+ materials for DIY masks:

Requires: fabric, elastic element

Open-source project

Here you can find how to learn photogrammetry, The dedicated Blender add-on tutorial, the .stl files, and printing profiles.

We decided to use photogrammetry to obtain a 3D scan of the wearer face since it’s the easiest method and can be performed using any smartphone camera. It can also be used a standard 3D scanner if available.


There are several 3D scanning methods.
Among the various 3D scanning possibilities currently available, photogrammetry is an immediate process and within everyone’s reach, achievable without having to purchase dedicated technologies.
It is a matter of taking a series of photographs even with your mobile phone, at a minimum distance of 1 meter from the subject, starting from one side of the face to the opposite side.
It is necessary to place reference points together with the subject to be able to re-calculate the right proportions during the export phase.

Follow our instruction in the download above

To get the 3D face file, you need to transform the images into mesh.
For this operation we recommend the use of this software: RealityCapture
At the end of the reconstruction, just export the scan in .obj extension.

Follow our instruction in the download above.

WASP has developed a process to create custom masks starting from 3D face scanning through modeling with Blender 2.82. Thanks to Alessandro Zomparelli, collaborator of WASP, a dedicated Blender Add-on was born: My Face Mask Blender add-on that facilitates and automates the customization phase with specific commands until the export of the template.stl file.

Download  Blender 2.82 here: https://www.blender.org/download/releases/

Download MY FACE MASK add-on Blender 2.82 and instructions here: https://www.3dwasp.com/en/my-face-mask-addon-blender/

We recommend 2 types of materials for printing the template:

PCL: Polycaprolactone is a bioplastic already in use in the medical sector which is extruded at 100 ° and can be further modeled at the end of printing in hot water (60/70 °). It can be printed with all models of WASP 3D printers with 1.75 mm filaments with WASP SPITFIRE Extruder and WASP ZEN Extruder extruders.

BIOFLEX: Bioflex is a medical certified TPE 27 Shore D (medical certification of type USP XXXII: 2009 Class VI and ISO 10993-4 / 5/10) for skin contact. It can be printed at 200 ° using 2.85 mm filaments, therefore usable with all WASP 3D printers equipped with WASP FLEX Extruder.

Cut the filter material to right dimensions and insert it into the mask.

By publishing this 3D application and how to replicate it, we want to make it clear that under no circumstances do we want to replace medical supplies. Our Team is available to develop tech projects at the service of the community.

Discover more about:

My Space Helmet

My Space Shield PET 0,5 mm WASP Protective Visor

mascherina 3d - MY FACE MASK

PEEK pellet 3d printing - WASP

WASP's new 3D printer prints medical-grade PEEK from pellet

Healthcare has always been a huge branch of the applications for additive manufacturing since its beginning. This sector is showing us how tangibly 3D printing can improve our lives but also challenging every new technology and inspiring innovation.

In this context, WASP is proud to unveil the results of its work on printing medical-grade PEEK from pellets with a brand new line of 3D printers: Delta WASP Tech line.

PEEK pellet 3d printing

Printing medical-grade PEEK makes possible to realize implants from digital designs with a material that has uncomparable performances at a relatively low-cost. This is something that can revolutionize the field of implants.

The idea of printing the PEEK implants from pellets came from the long research carried on with Dr. Villiam Dallolio on the creation of cranial prosthesis with 3D printers.

Tests show how the resistance of the prosthesis is outstanding with an extraordinary lightness. The prosthesis after the print can be also processed with annealing at 200°C in the oven to improve even more the mechanical performances.

For the future WASP is working on the complete system complete with software, printer, and material to produce the prosthesis from the CT of the patient everywhere in the world.

Another step closer to a world where technology meets basic human needs: WASP's philosophy.

The prostheses for syrian children are printed in 3d

Active in Damascus a laboratory donated by AMAR, WASP and Arche 3D

The little Syrian seems perplexed, maybe he doesn't understand well what's going on. Then he sees the colored artificial limb that was applied him in place of the missing right arm and his face lights up in a smile that warms our heart.

Yasser Al Khaled is trying his 3d printed arm
Yasser Alkaled and 3d scanning

This is one of the first 3D printed prostheses in the laboratory that the association AMAR Costruire Solidarietà Reggio Emilia, WASP and Arche 3D WASP Hub Mantova donated to the University of Damascus.

"Who knows - says Massimo Moretti, CEO of WASP - maybe that child lost his arm
just because of an Italian anti-man mine. Now he knows that not only weapons are produced in Italy

Yasser Alkaled e la scansione 3d

All stages of the birth of the 3D prosthesis laboratory in Syria

More than year ago Jean Bassmaji, a Syrian cardiologist who has been living in Reggio Emilia for several years,together with Carlo Masgoutiere from Arche 3D, arrived at WASP headquarters with a very special request.
Jean is the founder of AMAR, an association created to help his people plagued by wars. He learned that among WASP product there is the Digital Orthopedic Laboratory and came at WASP to ask for a discount on the purchase of a Digital Orthopedic Laboratory to install in Syria. Jean was amazed and touched when Moretti, in a rush, decided to offer the whole Orthopedic Laboratory perfectly equipped free of charge for the Damascus university - The offer includes ng both the printers and the training necessary to realize prosthesis.

Further to this first meeting a feverish work starts in order to produce deliver and install the laboratory in Syria . The relations with Damascus to involve the University are soon created, but the obstacles met during the path were innumerable. For example, it was necessary to create the proper conditions to have the machines safely shipped to Syria by ship. Meanwhile Professor Firas Al-Hinnawy (Faculty of Medical Bioengineering - University of Damascus), was in Italy, at the WASP headquarters, to attend a training course that allowed him to transfer the necessary knowledge of how to use 3d printers at best, to his students.

The laboratory with WASP 3D printers at the University of Damascus in Syria

WASP in Siria - Consegna laboratorio di protesi in 3d al prof Firas

For more than one month we have had a Delta WASP 4070 INDUSTRIAL and a Delta WASP 2040 PRO, plus a scanner, a pc, a monitor and some technical materials, that form the equipment of the laboratory at the university campus in Damascus. Here people work to give relief to hundreds of about 50 thousand mutilated in the country. Together with Jean Bassmaji, Carlo Masgoutiere went personally to Syria for about ten days and contributed to the further training of students and professors.

WASP in Siria - Studenti al lavoro nel laboratorio di protesi in 3d a Damasco

Carlo returned enthusiastically: "There is great excitement - we were welcomed with all the honors. Now the goal is to train as many people as possible and make more and more sophisticated prostheses. The exchange of knowledge is virtuous. For example, a Syrian girl has already developed a system with ten movements, which are stored on the existing arm and transferred to the mutilated part”.

"The two bases of the bridge have been laid - adds Massimo Moretti - Now groups of people so far apart can give shape to the same thoughts. What is planned in Damascus can be materialize in Italy and vice versa, without problems of borders and checkpoints".

Students and teachers at work to give relief to war victims

"Finally, our dream has become reality," says Jean Bassmaji enthusiastically. "The Orthopedic laboratory for Syrian mutilated people has been installed at the Faculty of Mechanical and Electrical Engineering in Damascus. Here about ten students (mostly women) are working and four teachers every day. In Syria we met a country exhausted after nine years of war. But Syria is also tenacious and full of hope. The population is friendly and hospitable. But our work is certainly not finished yet: the laboratory must grow and become more and more a scientific reference point, as well as a human goal".

Thanks are due to all who have concretely supported the AMAR, WASP and Arche 3D project. In particular the Boorea social cooperative, the Reggio Emilia’s Arci circles, the artist Sergio Fermariello and many private people from Reggio Emilia, Chieti, Mantua, Naples and Lauria (Potenza).


Application of FDM technology to traditional orthopedics

A case history of 3d printed orthopedic braces

La Milagrosa orthopedics is a Spanish company that is part of the WASP Med network since 2018. Thanks to the close collaboration between Inma López Hita, head of digital design and additive manufacturing, and WASP Med, it was possible to find new solutions for 3d printing in medical application. La Milagrosa works in the world of 3d printed orthopedic braces since many years: it produces solutions for orthopedics using digital manufacturing. WASP 3D printers, in particular our 3D printer Delta WASP 4070 INDUSTRIAL 4.0, made it possible to have big size printings, creating even very large polypropylene pieces.

3d printed orthopedic corset

3d printed orthopedic corset

An important example is the one of 3D printed orthopedic braces in the correction of vertebral dysmorphism produced with FDM technology. The creation of a printed corset provides an innovative process compared to the traditional manufacturing realized with plaster cast. It follows three steps: a quick and easy 3D scanning, a 3D modeling phase with very large possibilities of customization and finally the 3D polypropylene's printing.


It is possible to apply this process not only for the resolution of chronic situations but for bone fractures which, usually, would imply a full limb cast.

3d printed orthopedic brace for femur's fracture

3d printed orthopedic brace for femur's fracture

In this case study a brace has been realized to resolve a femur's fracture in a newborn: it is the alternative to an invasive plaster which covers from the belt to the feet. This solution offers a greater mobility, which is essential in the early years of growth.

3d printed orthopedic brace for leg

3d printed orthopedic brace for leg

Another application is when there are external fixators and a cast is not possible: thanks to this support the knee is immobilized and it's possibile to start to place the foot on the ground.

3d printed orthopedic hand devices

3d printed orthopedic hand devices

The 3D printing opens up new scenarios also on hand devices. It is possible to design ad hoc solutions for the individual patient who had interventions on nerves or for cysts removal. With these devices fingers could drive with a gradual use of the force to regain mobility. The components are lightweight, minimally invasive and aesthetically interesting.

3d printed orthopedic hand devices for kid

3d printed orthopedic hand devices for kid

In all the situations, in addition to the benefit for the patient, it is always evident the advantage of digital fabrication technology in terms of process: scanning is immediate and minimally invasive, modeling is highly customizable and there are no materials to be disposed of.

3d printer for orthopedic braces

3d printer for orthopedic braces

3d printed orthopedic braces with Delta WASP 4070 INDUSTRIAL 4.0 reduces costs and returns a robust and reliable finished product, a guarantee given by the characteristics of the machine and by certified materials.

Add-on Blender 2.8 course: digital manufacturing for the medical sector

Add-on Blender 2.8 course: digital manufacturing for the medical sector

WASP organizes a 3D modeling course for Blender 2.8 dedicated to the medical world, in particular to the specific medical add-on developed by WASP Med. The course is designed for orthopedic professionals and 3D modellers who want to learn how to use this digital fabrication tool during their daily work.

Add-on Blender 2.8 course – digital manufacturing for the medical sector

Our course will take place in September on following dates 13th, 14th, 27th and 28th. We’ve organized 4 days dedicated to the basic and advanced knowledge the proper one you need to have to use our WASP Med Add-on Blender 2.8. This Add-on is the important result of a year work of WASP Med team in the digital orthopedics sector development. The course will be organized for a maximum of 12 participants and a minimum of 5 to ensure a good teaching result and a one-to-one verticality.

Every day will be divided into 2 parts:

  • 4 hours in the morning with theoretical lesson with Prof. Zomparelli
  • 4 hours in the afternoon with practice together with the two WASP tutors.

It will be translated in English.



PROGRAM Blender Course 2.8

h 09.00 – meeting
h 09.15 – lesson
h 11.00 – coffee break
h 11.15 – lesson
h 13.00 – lunch
h 14.00 – practices
h 18.00 – end lessons


Organic vs mechanical modeling
Modeling of low-poly parts
Bridging, extrusions, erasing and moving faces


Mesh import and scans
Modify and manage an imported mesh
Use of modifiers for anatomical adaptation


Add-on step-by-step use with details
Study of the functions inside Add-on in Blender 2.8
Modify the mesh that comes out from the Add-on with additional functions


Specific cases based on participants’ feedbacks
Workflows’ creation

Blender Course 2.8: useful info

On September 13th, 14th and 27th the course will take place in Bologna, in a location easily accessible from the train station. On September 28th, it will take place at WASP in Massa Lombarda where some practical aspects of 3D printing will be tested. The course includes 32 lesson hours + 15 assignment hours at home, for a total of 47 hours.

Video: https://www.youtube.com/watch?v=hEZ6PulqPnQ


Alessandro Zomparelli

Since 2011 he has been member of Co-de-iT, his background in Engineering and Architectural fields drove him to explore the opportunities of computational design in combination with 3D printing technologies at different scales, from architecture to human body. He is busy with both speculative and commercial projects, from masks to prostheses, fashion accessories to medical products.

Since 2015 he has been  author and developer of Tissue, an open-source add-on for Blender with the aim to introduce specific Computational Design workflow, like surface tessellations, without the need of nodes or programming skills. 

He is currently Contract Professor at Accademia di Belle Arti di Bologna and at Istituto Marangoni (Milan), where he teaches digital design techniques for product design. He is also tutor in several international workshops about computational design strategies in Architecture and Product Design.



The course costs only Euro 1.200 + VAT (22%)

If you are interested to join the course please register by filling-in the below form (send your application as soon as possible because it closes on reaching the 12 participants).

You will receive a Proforma form with correct due amount and bank details for the bank wire transfer then.
Bank details: IBAN: IT21O0854267570023000095117
Transfer reason: Add-on Blender 2.8 course: digital manufacturing for the medical sector. The registration will be confirmed you by email upon receipt of payment.


WHAT: Add-on Blender 2.8 course: digital manufacturing for the medical sector

WHEN: on 13th – 14th – 27th – 28th September 2019, from 9 a.m to 6 p.m

WHERE: Bologna & Massa Lombarda, (WASP).

TARGET: orthopedic technicians, medical professionals, students

BRING WITH YOU: your laptop.

For this edition registrations are closed.

Ask informations for the next editions filling the form.  

    * I hereby authorize utilization of my personal data for the purposes of processing my request. Such personal data shall be processed in compliance with the information contained in the privacy policy

    WASP MED Add-on Blender 2.8

    WASP MED developed an Add-on for Blender 2.8

    The open-source 3D software for P&O now exists

    WASP MED Add-on Blender 2.8

    In this contemporary scenario of a global population growing more and more health care is going to be one of the main challenges of our future: according to 2018 GDR research, the global prosthetics and orthotics market size is expected to reach USD 12.28 billion by 2025.

    WASP for the Healthcare

    Since the beginning WASP considers health one of its main themes of research, as one of the man’s basic needs. For this reason in 2015 WASP MED team was born, working specifically on the needs of this huge field. The development of the 3D printers and materials for medical use it’s not enough if doctors and professionals don’t have tools to apply their knowledge. To face this need WASP MED developed an Add-on for Blender, the popular open-source 3D software: WASP MED Add-on Blender 2.8.

    The idea is to fill that gap between professional software, often very expensive and rigid, and open-source software, which are powerful but not specifically designed for medical use. The development has been carried out by Prof. Alessandro Zomparelli, teacher at Accademia di Belle Arti di Bologna and Blender developer since years. His previous works on shaping objects based on the human body has been the key to get a powerful tool for designing easily complex shapes on 3D scans.

    Why Blender?

    Blender is a perfect manifesto of an open-source platform that escalated to be one of the best products for 3D modeling in the world of animation and not only. Each year in Amsterdam is organized a Blender Conference. Here the most innovative applications of the software are presented and shared: from physical simulations to medical tools, covering a wide range of professional and non-professional uses. Blender 2.8 is an open-source software: it is downloadable for free and its development is shared with hundreds of users around the globe.


    What’s WASP MED Add-on Blender 2.8?

    It’s a free Add-on that runs on Blender 2.8 and contains step-by-step commands to model a shape on a 3D scan. The final shape is suitable for being 3D printed, compatible with the 3D printer.

    The Add-on feature tools for:

    • fixing the scan
    • making corrections and modifications
    • cropping undesired parts
    • drawing the shape of the orthoses
    • managing thicknesses and borders
    • exporting the mesh for 3D printing

    The Add-on also gives freedom of intervention with all native Blender tools to solve more complex necessities.

    The future of the Add-on

    WASP imagines this as a first step to create a collaborative community around the world using open tools to give solution to main health themes. This could give access to a huge amount of the world’s population to medical devices that now cannot afford or don’t even exist in their country.

    The 3D printer for Orthopedy

    In the medical sector, innovation is the key to advance the health care. WASP MED for years has worked not only to the development of this new open source 3D modeling software, but also to design and build customizable 3D printers for the orthopedic sector. The DELTA WASP 4070 Industrial 4.0 printer is the most performing printer model, adaptable to the professionals individual’s needs for the development of medical devices.


    Story of a 3D printed prosthesis

    CAD Ortopedia tells us how they printed a prosthesis for Mr.P

    Today we're pleased to present you a case study of a member of WASP Med team, a work by CAD Ortopedia with a patient amputated on the leg.
    The work is an interesting application of 3D printing in the creation of a leg prosthesis, with a peculiar mixed technique between traditional and digital.

    Patient situation

    "Mr.P, transfemoral amputated, presents various issues in his actual socket. For this reason, his movement possibilities are compromised: painful zones of hyper pressure, zones discontinuity, that lead to an important variation in terms of volume and dimensions of the stump during the arc of the day.

    Acquiring of the shape, correction and realization of the prosthesis

    His stump has been scanned with the help of a structured-light metrology scanner. The data has been elaborated with the software by our informatical technician and orthopedic technician.
    Suddenly we went on with the prototyping of a trial socket in PLA, a very thin one and with just two shells, so super light. This socket presented also holes in all the shape, allowing in the measurement phase a more accurate and proper evaluation. Starting from this analysis we developed a socket in silicon that followed the modifications and the fixtures studied thanks to the 3D printed product.

    With this approach, the issues expressed before went reducing in the days, and eventually the disappeared completely. The walking has definitely improved and the stump is visibly more tonic.

    Considerations on the process

    This experience is interesting because today there isn't a real tested method for these kind of situations. Usually the problem is solved realizing a lot of different trial sockets that are modified until you don't get to the solution. Clearly this method required a lot of time and work for the measurements and the tests.
    The use of 3D printing and scanning reduces a lot the time of measurement, production of the socket. Also the PLA being easily thermoformable helps a lot in the adjustments.
    Finally part of the work is done by the machine and not by a person, saving time for the production and focusing the attention of the technician in the phase of the test."

    Cranial prosthesis is improved with 3D printing

    The innovative work of Dr. Villiam Dallolio

    Each year, only in Italy, almost 2000 cranial prosthesis are realized for operations of cranioplasty.
    These operations, complex for their nature, are remarkable for an high failure percentage typically due to the raw manual techniques of realization of the prosthesis.
    Today with additive manufacturing we already can create custom prosthesis. Even if some structures in Italy already have them in use they are still a weak solution for their costs and time not appropriate for the operating room.
    Here is were enters the work of Dr. Villiam Dallolio, a neurosurgeon based in Lecco, Italy.
    Since 1999 he's been experimenting to reduce the distance between 3D printing and Neurosurgery.


    An indirect process

    The key point of the process developed is in the radical change of approach.
    The idea is not fabricating directly the prosthesis with the 3D printer, with unsustainable costs and times, but thinking of a system that allows designing out of the operating room in an optimized process concluded by the realization of a scaffold(negative).
    The starting point is a TC of the patient that can be translated with appropriate software in an high-fidelity 3D model. From here starts the modeling of the cranial prosthesis(positive) thanks to systems of mirroring and joining. In this phase we can think about the integration of some features. One example is the predisposition for the metal tabs. Another is designing a shape that can fix the muscular atrophy typical of many clinical cases.
    From this shape, we model out the scaffold(negative) in which the material with be cast.
    The scaffold, in certified material, is sterilized in the autoclave during the operation and allows the casing of bone cement. The strength of the system is the maintenance of the exact shape designed with the CAD.

    Advantages of the system

    With this method, the operation is faster and reduces a lot the risk of unfitting for the prosthesis thanks to the superior digital design.
    The final material is bone cement that maintains all his wonderful properties, it's easily available and already respects all the certifications.
    The aim of the work is to replace gradually all the obsolete system today in use with this convenient technique that would radically improve the approach in the operations of cranioplasty.


    Today Dr. Dallolio's team is already providing the possibility to create cranial prosthesis with digital designing with the use of 3D printers and negative molds in silicone. Clearly is something not comparable to the convenience of the system described above, but is an half way.
    Perspectives are wide and interesting, most of all because this kind of system would be suitable for every kind of implantable bone prosthesis, not only the ones for the skull.
    The scaffold system is opening up to a whole new scenery in the surgery of tomorrow.

    The orthopedic corset 3D printed in polypropylene

    Lelio Leoncini marks again a standard in the digital corset

    2018 could really be the year of the explosion of 3D printing in the orthopedical field.
    A lot of professionals are starting to work, reinventing their work in the direction of digital fabrication.
    However there's someone marking the road of the innovation, this one is Dr. Lelio Leoncini that since 2014 is experimenting and creating digital solutions in his field of competence: physical medicine and rehabilitation.
    Since then together a deep friendship and collaboration started with WASP and brought to great results.
    In 2016 the web went crazy for this video showing the first generations of 3D printed corsets created by Dr. Leoncini, an unexpected application for 3D printing at the time.
    With his peculiar determination and creativity, in these years the idea of creating new solutions for scoliosis has become each day more concrete and credible and taking shape in the creation of the Digital Orthopedic Laboratory.
    Above all the main innovation has been the developing of the polypropylene.

    The turning point of polypropylene

    Who fabricates orthopedic corsets knows well how important is the material used. The consistency that defines the corrective pushes and the resistance that prevents the object from breaking. Not least the possibility to work on it easily.
    In these years the research on the right material hasn't been easy: every solution, compared to the polypropylene traditionally in use was too rigid or too flexible and always too fragile.
    A fragility that you can't afford when realizing an orthesis that has to last years.
    A long work that featured TreeD filaments, Dr. Leoncini and WASP  brought to a radical turning point: the polypropylene.
    Who works in 3D printing knows that for a long time this material has been considered "impossible to print" decently due to its peculiar behavior during the deposition and for the difficult adhesion to the bed.
    In time a lot of plastic producers tried to develop their version of the material with compositions that made it easier to print but with disappointing mechanical performances comparing to the injection molded.
    The real result has been that usually people tried to replace it with materials familiar to the world of 3D printing(ABS, nylon, PLA) settling for the offered solutions.

    In 2017 from a long experimentation a new material was born, a real polypropylene developed by TreeD filaments that in the tests was found to be at the same time compatible with the printing and ensuring mechanical performances up to 95% similar to the injection molded polypropylene.
    Even if it's not in the category of  "easy-printable" materials is now possible to create stunning stuff.
    Furthermore, it allows the professionals in the world of orthopedy to work with a familiar material, robust, easy to finish, just good.

    New busts for impossible cases

    Another field of research was designing at 360° over the traditional limits.
    Thanks to digital fabrication it was possible to create custom solutions to patients with more complex situations for example corsets with very complex shapes or with the necessity of support even in the head.
    The 4 column scannin system has demonstrated to be the best way of acquiring anatomies for children, for people with difficulties in breathing, for the ones with compromised moving.
    Everyday these technologies seems to open up to new applications.
    By the time the tools and the knowledge are moving forward fast. Every year printing time reduces and the quality of the products increases.

    Today many professionals working in orthopedy are getting close to the world of digital fabrication, a world that attracts and has a lot of space for experimentation.
    The hope is seeing in next years the results of the long work that is creating a culture of the new technologies in the world of orthopedy.
    This is surely a challenge but one that is worth accepting.

    One Hand for Syria: 3D printed prosthetic limbs for Damascus University

    Arche 3d as a WASP hub thanks to the connection with the cardiologist Jean Bassmaji president of AMAR, the association of Reggio Emilia that deals with humanitarian aid for Syria has produced a collaboration. The aim is to set up a laboratory for manufacture of higher artificial limbs at the Damascus University of Mechanical Engineering in the course of Bio Medical Engineering. The purpose is to design, produce and distribute arts or parts of them to war mutilates for free and without distinction of age, sex, ethnicity or religion .

    The laboratory consists of two 3D printers Delta WASP 2040 TURBO2 and a 3D scanner offered by the WASP company.

    The project is based on a consolidated process of the application of the new digital manufacturing technologies through several steps:

    • the scanning of the stump of the amputee,
    • the digital data processing,
    • the possible modification of project files already elaborated for the correct sizing or for the different dysfunction,
    • the 3d printing of the same arts and the subsequent composition of the same.

    PROJECT ONE HAND FOR SYRIA: 3d printed prosthetic limbs for Damascus University.


    Type: modular

    3d Printer: Delta WASP 2040 TURBO2

    Scanner: 3D sense

    The AMAR association is committed to supporting the cost of materials needed for a calendar year. Any assistance and advice related to the equipment provided and possibly a training course via SKYPE will be carried out by Arche 3D. They will also eventually will undertake to process the data retrieved from the University and to support the project even remotely by sending the files to be printed or by sending the projects in order to make the operation more effective.

    In parallel, an online database will be created and shared for the cases addressed in so as to have easier access to various types of possible cases of amputation and therefore an optimized response over time and in the design modalities in order to make the process better is faster.

    Arche is already in contact with the University to develop an online layout of the possible laboratory, which will be effectively active once the machines arrive at their destination, expected for the month of May, following an on-site visit by part of the Di Arche 3d team and Dr. Bassmaji.

    The aim of the project is to produce as many prosthetics as possible, at full capacity it is possible to structure two per day, one per printer, which is to train and disseminate knowledge on the use of additive manufacturing technologies and digital design, for the possibility with the same machines and the same process of designing and producing objects and components useful to humankind.

    PARTNERSHIP: Comune di Reggio Emilia, Comune di Mantova, Fondazione Mondinsieme, Associazione AMAR, WASP, Arche 3d, Creative Lab, Università di Damasco, Fab Lab Mantova, HelpyTechnology, NUR.


    The Porzio and WASP medical skills meet to project innovative solutions with 3d printing.

    Live and love your Limitless Life is Fabio Secci' mantra, surf paralimpic athlete  who learned how to face up to his life challanges with passion and tenacity. On 4 May, from London, he came to the orthopedic company Porzio in Udine for the design of a prosthesis he himself describes as an "artwork", whose father is the engineer Marco Avaro. In less than 18 hours, the Porzio team developed a lightweight (less than 800gr) prosthesis with a complex shape, totally 3D printed (including headphone parts) with a Delta WASP 4070 printer.


    "I am totally satisfied with the result," Marco Avaro says, "it took less than 18 hours to achieve an absolutely perfect extension, characterized by extreme sturdiness thanks to a new conception filament".


    With this new prosthesis on May 29, the athlete, Fabio Secci, has been very successful at his first Triathlon held at Dorney Lake, UK (where the Olympic Games took place in 2012), fulfilling 400 meters of swimming, 10 km of bike and 2,5 km of racing. The upcoming competitions where the new extension is going to be tested are many, including the tough mudder, 10km hurdles where the athlete aims to cut the finish line along with other adaptive athletes like him.


    Fabio Secci was the first Sardinian to represent Italy in the stand category at the International Surfing World Championship in California in 2016. He is an instructor for Adaptive Wakeboarders in wakeplus and wakeupdocklands. With the purpose of transmitting his love for sport, he founded F-Yourlimit in London, a project that aims to introduce new adaptive athletes to the Water Sports world with the purpose of helping them to push beyond their limit simply trying to live a life in harmony with themselves and their own body. In addition, this project aims to support the research on innovation and development in sport field.


    Fabio's mission is linked to the new 4.0 route, undertaken by Porzio with the introduction of the five PorzioLAB 3D printers by WASP, a leading company that designs and produces 3D printers entirely made in Italy.


    Sardinia Wakeboarding from fabio secci on Vimeo.

    For further information:

    Alessia Siega – Marketing Porzio Group

    a.siega@porziogroup.it - 0432 1890930


    Press office WASP


    3D Printing has an answer to scoliosis

    3D Printing has an answer to scoliosis

    You can find all the material on the research of 3D printing in the medical field in the section of our site WASP Med.

    WASP Med and IOR, Technology and innovation in the medical field

    WASP medical group meets the researchers of the  Orthopedic  Institute Rizzoli  in Bologna. To make the point on the  development  of the projects linked to the introduction in the medical field of the 3D printing  and on the introduction of the new training course: “Tecnico per la fabbricazione digitale biomedicale”.Technician  in  virtual biomedical fabbrication.


    WASP Med, a working team which assemble researchers ans professionists in the medical field,  with the purpose to offer  tailored solutions able to improve the doctors job and the patient wellness, met on Friday 25th November 2016  IOR 's (Istituto Ortopedico Rizzoli di Bologna excellence center in the orthopedics and traumatology fields)  technicians and researchers. IOR has been dealing with 3D printers applied to medical field for several years. During the event,  WASP Med team has introduced the partners, the projects and the latest developments in the 3D printing applied to medical field and a new training course.

    Technician  in the virtual bio-medical fabbrication

    As explained by Massimo Moretti, WASP's CEO, the society is going to introduce a training course  “Tecnico per la fabbricazione digitale biomedicale”. Its purpose is to train a professional person able to realise medical support-parts 3Dprinted with the help of digital acquisition instruments, dedicated softwares and 3D printing machines. A professional figure  expected to find  several application fields in a near future, as 3D printing is getting an irreplaceable role  in medical field due to its innovations and advangages for the patient but for the  medical staff too.   The possible realization fields go from the educational performaces or preparatory study of the  muscle tissue, of the bone or dental apparatus, to the construction of customized supports for scoliosis and lordosis theraphy; for surgeon guides and to make some surgeon intervention easier , from not planted estetical and functional prothesis to the construction of customized surgeon instruments.

    Prothesis, corsets and insoles: the WASP Med group successes

    One of the first  to use a WASP printer, getting a big improvement in the scoliosis therapy compared to the traditional methods, was doctor Lelio Leoncini, phisician director of the Medical Center Sanatrix of Rionero in Vulture, who showed to the Rizzoli staff more confortable and accurated  corsets, tutors and insoles  compared to the traditional supports, specially if compared to the classical plaster casts, little practical and not easy to be realised.

    Among the team WASP Med-results promoted during the event at IOR, the extraordinary prothesis realised by Marco Avaro, director and prothesis-technician at the Orthopedic Laboratory Del Bene Fabio in Trieste, are  noteworthy. In fact he has been realizing replacement appendages using Delta WASP for several years, helping  paralized athletes, victims of antipersonnel mines and fire arms: supports in light and resistant materials that have allowed to amputated people to start walking running and even surfing again.

    Innovation in the material study

    In the WASPmedical application it 's of foundamental importance the study of the materials and of the filaments with the aim to obtain more and more resistant and flexible objects at reasonable prices.  Dario Pizzigoni from TreeD Filaments, works in the polymers field: He is the “plastic” expert. He explains “We work a lot with composite materials made up of several polymers or by one polymer united to a different element, like carbon for example. An advantage in the use of these  materials is the biodegradability . This is a widly expanding field , we are at the beginning of our research : there are still a lot of new polymers to test.”

    Interdisciplinary perspective  and technology: medical future

    In addition to the single and specific technological developments, central element in the 3d printing medical application is the interdisciplinary perspective, the twine of different “expertises”, skills belonging to different fields, from design to projecting from engineering to medicine up to competences in legal field. A shered vision carried on by the IOR research-team, whose coordinator is the engineer  Alberto Leardini, chief of the Institute Analysis Laboratory, who works with the aim to realize tailored prosthesises. “We cannot think to take care of just a single field – the two engineers  Leardini and Leonardo Vivarelli, from Prometeo Laboratory - explain – The medicine future is in the inter-connection of different skills with the foundamental help of technology, in the direction of the development of more and more customized equipments and instruments”. And this is the direction followed by all WASP Med team.

    3D Printing and the medical application: Lelio Leoncini’s amazing creations using WASP 3D printers

    One of the field where the 3D printing has given its best results, and where promising developments are going so far to be imagined in a near future, is the medical field  and in particular Orthopedic. Scoliosis is a widespread disease but it is so difficult to treat that it often impose the use of uncomfortable and expensive orthopedic corsets.  In 2014  Lelio Leoncini, a doctor specialized  in Physical Medicine and Physical Therapy, from Acquaviva delle Fonti (Ba), Medical Director of  the  Medical Center”Sanatrix” in Rionero in Vulture (Potenza), has started to test the 3D printers using a  Delta WASP 4070 to realize orthopedic corsets. Now Leoncini joins WASP Med, a group committed to the research and whose aim is to improve health and wellness.

     CorsettoEsoscheletro2Scoliosis and  3D printing

    “From an orthopedic and scientific point of view, the 3D printing allows to perform on scoliosis in a a more efficient and effective way than the handmade production” he explains. -. “Through  the virtual project, you find out how a scoliosis will develop; the production costs decrease considerably; you don’t have the problem to clear out the materials and you speed up production:  a technician can hand-make a couple of corsets a day; using the 3D printing you can double the quantity and with a better quality.”

    In addition, the resulting product is particularly effective: “It is  much more anatomical, it does not annoy the patient who, consequently,  can wear it for a longer time; then allocating uniformly the loads,  it acts in harmonic way then, last but not least, it looks nicer”.


    From the plaster cast to the Shogun Filament

    Doctor Leoncini’s research starts from the bottom, from the several needs of doctors, orthopedic technicians and from patients (from the youngest to the oldest) and from the examination of the critical and restrictive actual systems; all problems that can be solved using new technology and sparing money too“. A corset construction has always been a difficult process  because it’s full of scientific disputes. “This is one of the reasons why many accomplished schools of thought exist” he explains -. “It is fundamental to overtake the plaster cast technique, and get a precise body-model realized with scanner – this allows to shape it in a very precise way, giving advantages not only to the operators but specially to the patients. Using this new technique I have been able to achieve a very high level of precision, for example you can make amendments and revisions of the model, thing which would be impossible using the traditional and more common technique of the plaster cast.”.

    The last series of corsets has been realized using a new fiber: the Shogun Filament, which resists to high temperatures. It does not present the PLA problem of thermo-frailty, preserving the possibility to be thermo-shaped more than once; besides it has physical characteristics similar to the polyethylene commonly used for corsets. “There should be more other fibers to be tested“  the doctor continues -. A wide range of new fibers for medical-use is now spreading  but we need to test each of them according to the several applications; Actually the Shogun from TreeD Filaments is perfect for corsets.”

    The corsets realized in the last months

    Modello Cheneau modificato

    - The modified Cheneau Model


    It has a punched weave where the corset is not often mechanically solicited, on the contrary the areas of the underarm hold and of the pelvis, are compact to support the bigger pressure. Two kinds of weaves have been realized:  the first  (smile shaped) is suitable for 3D printing and for a balanced strength distribution, the second  is  grasshopper which allows a quicker and more precise printing and  the realization of a lighter and more resistant corset.


    - Esoskeletal Corset


    Due to the particular  “underarm and pelvis holds” it allows to obtain an anti-gravitation effect on the spinal column, that’s why it is suitable in cases of advanced osteoporosis  with vertebral collapse or after a surgeon intervention on the backbone where it is necessary a period of unload on the vertebral column. The same kind of corset can be used also in cases of iper-cifosis in the  evolutionary age, changing in the modeling-phase  some strength-vectors.


    - Chair Corset

    Realized against body and pelvis acquisition while sitting using ring sensors actually realized by WASP. Studied on purpose for serious scoliosis which forces to remain sitting and in cases of posture disabilities.

    Orthopedic insoles

    It has been realized a very simple structure: a structure which allows an under-load foot  360 degree acquisition. This is a fundamental aspect because a no-load acquisition would produce a model which does not correspond to the morphological and functional foot-change. Orthopedic insoles: Insole printed in TPE plus stirene, Printing of the positive foot model, Proper receptive orthopedic insoles.

    - Insole printed in TPE plus stirene

    It is suitable to be used with classical materials. In  short a special antibacterial fiber will be available, Characteristic which is not present in normal and more common materials.

    - Printing of the positive foot model

    Some insoles, like those for diabetics require the use of   some special materials, therefore it’s possible to print the patient foot on which thermo-shape the materials.


    Wrist and forearm with a prevent-accident-fiber,  realized with Grassopher.



    Canoeing and Surfing: two Italian Athletes at the Paralympics and Isa World Adaptive Surfing Championship

    Veronica Yoko Plebani is ready for Rio Paralympics. Fabrizio Passetti is preparing for the ISA World Adaptive Surfing Championship in La Jolla – California. They are two Italian Athletes with a rich palmares of trophies and success. They have in common that They use Prosthesis 3D printed by Marco Avaro, Biomedical Engineer who is part of the WASP Med team. He works with a Delta WASP 4070 and three Delta WASP 2040.

    Veronica is a canoeist and Fabrizio a Surfer. “I’ve made a hand brace for Veronica – says Avaro –Fabrizio instead needs a carbon fiber prosthesis for high-level performance in extreme conditions.” They are enthusiastic about results and they embody the extraordinary results we can obtain with 3D printing.

    Prosthesis and Braces 3D printed with a Delta WASP by Marco Avaro - Biomedical Engineer

    At the Orthopedic - Lab “Del Bene Fabio” in Trieste, the Italian Engineer indefatigably works with his DeltaWASP Printers realizing more and more sophisticated prosthesis. “This work is based on using high-quality filaments, produced by TreeD Filaments, and the fast and accurate printers manufactured by WASP. Today the 3D printing has become extremely accurate and sophisticated. We’re printing objects with tolerances of 0,2 mm.

    It’s important to understand that a Prosthesis is a customized medical device must respect regulations and needs a medical prescription. Many reliability tests have been conducted. Filaments have been certificated and now we’are writing specifications.

    We’ve builded a good relationship with Marco Avaro. In this period he is working with a new Extrusion System. He is experimenting the new Full Metal Extruder and he is very enthusiastic: “Its peculiarity is to homogenize prints, making a strong and tenacious product. I’m very satisfied – says Avaro – it’s a bulldog”.

    Here an amazing article by 3dprinting.com  https://3dprint.com/148356/waspmedical-3d-printed-prosthetics/.

    Lelio Leoncini

    Lelio Leoncini of WASP Med team recounts the 3D Orthopedics

    Scoliosis is the black beast of Orthopedics. 3D Printing permits to make great strides to perfect the current method of acquisition and production, offering a better cure for the body dysmorphia.

    Lelio Leoncini, Surgeon specialized in Physical Medicine and Rehabilitation, is fully convinced about this and since December 2014 he has been working with a Delta WASP 4070, experimenting orthopedic corsets.

    As is known, corsets are the only one way scientifically-proven to cure vertebral dysmorphia. "First of all I looked for an instrument (Rasterstereografia-Formetric 3D) that permits to constantly supervise without X-ray examinations the evolution of scoliosis - says Lelio - This experience made me able to identify the critical points of orthopedic corsets and their effectiveness, and it was an incentive to search for new technological solutions".

    Which advantages we can find using a CAD-CAM System and 3D printing compared with the current method with a plaster cast?

    CAD-CAM acquisitions: low costs infrared sensors; simultaneous acquisition of all the torso in half a second with the possibility to make corrections in this phase; possibility to work in the dark; acquisition space reduction; a more accurate system with the possibility to better control corrective actions; modeling in 30 minutes; disposal of plaster cast.

    3D Printing: no waste and possibility for recycle corsets; the possibility to post-modeling corsets; low costs; low weight; elimination or reduction of armors; to improve the aesthetic quality.

    "Corsets have to be accurate for a good therapy - says Leoncini - It's indispensable to know the biomechanics of the rachis and corrective principles of the Torso orthoses. The synergy between the Medical Doctor and the Orthopedist is necessary (...) and also the digitalization of the orthopedic workshops".

    Lelio is sure that the medical environment needs always a technology implementation. "I've always been interested in technology. (...) Medicine is a science and (...) there is always the possibility to develop. The innovation is the right instrument to cut down barriers and give opportunities to disadvantaged people".

    Maimed in a minefield, now Niazai can run again with a 3D printed prosthesis

    Niazai comes from Afghanistan. Some years ago he blew up for a minefield explosion.

    “I met him for the first time in Trieste – says Eng. Marco Avaro – he was using a sort of plastic prosthesis made as best he can and fixed with rags. The stump was bad, some edemas were becoming infected”.

    Immediately Marco made for him a new provisional prosthesis, free of charge. But Niazai needed also a house and food, so the Ics of Trieste (Consorzio italiano di solidarietà – Ufficio rifugiati) found a solution.

    He became Refugee with the Dublin Regulation, Niazai obtained the Residency Permit and Health Care from the Ass 1 (Azienda servizi sanitari) of Trieste.

    Now Marco has made a new prosthesis 3D printed with a Delta WASP 2040 TURBO and, as you can see in the video, Niazai can walk again. “See the eyes of this man – says Marco Avaro – Could you put a barbed wire between you and him?”.

    A prosthetic hand with a Delta WASP 2040

    A very simple prosthesis projected for people who has lost fingers or a piece of palm, realized with a Delta WASP 2040 by Enrico Perrucci (Cosmo3D). He belongs to the Enable Community Fundation, an American Community dedicated to 3D printing for customized, low costs prosthesis free of charge. Perrucci is now working on an Assembly Kit to educate children into schools to understand disability.

    For more information here.

    Silicone prosthetics: low costs and high quality with DeltaWASP 2040

    As is now well known, the world of 3D printing is proposing solutions that were previously unattainable for those in need of a prosthesis. With a few dollars we can now produce a prosthetic hands in PLA or ABS. However a welcome innovation now arrives from the specific area of silicone prosthetics and the covers that can reproduce our limbs realistically.

    Erica has been working on it for just two years, experimenting with custom silicone prosthetics obtained through 3D printing. Thanks to her commitment, her ability and collaboration not only from WASP but from a full research team, her work has already raised the interest of both amputees and enterprises providing prostheses in developing countries and in America.

    Protesi DeltaWASP 2040

    Erica Buzzi is a sculptor and a silicone implants design engineer. For several years she has worked with orthopedic technicians, experimenting on how to apply the most advanced technologies. She is currently a consultant for the construction of aesthetic orthopedic centers for several Italian laboratories working in the field..

    In 2013, fascinated by the possibilities offered by 3D printing, she decides to stop by the WASP headquarters and the empathy was immediate. "I almost did not believe it - she says - all it took was a conversation with Massimo Moretti, I explained my ideas, my plans, my dreams. And he immediately made his machines and his team available."

    Soon thereafter the print and tests and verification process began for several solutions. "Starting from the scan and its post processing to improve the details, the process moved on to the g-code file generation - explains WASP’s Nicola Schiavarelli - The vertical positioning of the stamp was important to enable the highest definition of the mold. Apart from this aspect, it was crucial to speed up the printing process, so the piece was 3D printed totally empty. It would be possible to make it more robust by filling it with polyurethane foam, but it was not necessary for the first tests. In factthe first mold for the silicone prosthesis was built in 8 hours using fused filament additive technology.

    3D scanning - Nicola continues - is definitely very important factor. At this stage the acquisition of details is the most difficult part but it is also that which will ensure the best results. It also became clear that the layers created by 3D printing made it easier to obtain the skin-effect finish on the silicone”.

    Protesi silicone Delta WASP


    Protesi silicone Delta 2040


    "With FabLab Parma and Pocaterra Srl in Bologna we tested scanners and modeling software, while with “Con le Ali Piedi”, also from Bologna, we applied technologies on the silicon to actually fabricate the covers” adds Erica Buzzi.

    Low cost, high quality, customized implants. These are Erica’s research objectives and she can now legitimately claim to have concluded this trial with excellent results. "But we never stopped because in these very days we are developing a solution to provide integrated silicone prosthesis with ultra-light joints for children without arms. And the will be affordable specifically because they need to change through a lot of them as they grow”.

    3D printing enabled a reduction of the time necessary for the various stages of production. "Through the 3D scanning management software, a missing foot can be designed using the remaining one - we read on the www.protesiinsilicone.it website - so as to maintain the accuracy of shapes and details. With the 3D modeling, in the pre-print stage, the necessary molds for the construction of the prosthesis are built, along with those for the silicone cover. The free-hand, wax reconstruction phase is thus eliminated, as well as those involving casting resins and gypsum mold manufacturing. This beings considerable savings in time, material processing, laboratory equipment and highly specialized labor in certain phases of work. "

    For printing, Erica uses a DeltaWASP 2040 with 0.1 mm definition. "It gives a good feedback. And allows both to contain costs and obtain a very precise and qualitative final product ".

    Built in PLA (a material that does not interfere or contaminate the silicone hardening process), the empty mold is then filled with plaster. Part of silicone processing is done by hand. A curiosity: during certain stages of the process, such as sample preparation of colored silicone for the nails, or each patient’s color chart, even a simple and economical pasta-making machine can be used.


    Protesi silicone DeltaWASP 2040


    "With support form funds and facilities - Erica concludes - testing will be increasingly developed and refined in order to achieve further advances in technology and performance."

    The silicone implant prostheses made with current procedures are very expensive and thus beyond the reach of most people. The national health system does not cover them, or covers them only minimally, compared to market prices. Producing them with a better technology, at much lower costs cost is Erica Buzzi’s dream. That's why we now consider her a perfect WASPer.


    protesi Delta 2040



    WASP with ASPHI

    Matthew is a blind student at the University of Bologna, attending the Professional Educator course at the Faculty of Medicine. He’s doing his internship at the Fondazione ASPHI Foundation. These days, Matthew is exploring the shapes of the Empire State Building, 3D printed with a Delta WASP 2040. In fact he is actively involved, along with ASPHI experts and researchers, in testing the 3D printer that WASP has made available to the non-profit organization based in Bologna, that has been reaching out to people with disabilities through technology for more than thirty years. Matthew lost his sight when he was very young, and until recently he had only heard about, but did not know the real forms of Art Deco skyscraper, which is a symbol of New York City. Through this experience, we can say that Matthew can now "see" and learn through touch. 

    The establishment of a 3D printing laboratory in the ASPHI Foundation headquarters in Bologna is focused on developing a branch oriented to construction of objects and computer aids for people with disabilities. People who have the same rights as every one else and special needs, to which they or their families often find original answers and crafty low cost solutions. Through ASPHI’s experience, particualr attention will be paid to the contribution that people with disabilities can make, directly as inventors directly, or indirectly as carriers of specific needs, in the design and construction of technological solutions, aids and items that can help to improve the quality of life for everyone all: at home, at school, at work or at play. The basis for a relationship between WASP and ASPHI were laid down about a year ago and have further grown starting in November 2014, on the occasion of Handimatica. The national show and conference on technologies for disability dedicated a special section to 3D printers and the Mak-ER network. The collaboration finally began to take form. "We have been following the the theme of aids, and particularly those that a disabled person could personally manufacture - said Rossella Romeo of the ASPHI Foundation – We know that several university research centers have already begun experimenting with 3D printing applied to the world of disability and also some FabLabs have been particularly sensitive to this issue. We were looking for a 3D printer manufacturer that was willing to cooperate with us.Partnering with WASP was the most natural thing."

    There are more obvious reasons for this ongoing collaboration, which WASP holds particularly dear. One is local, that is, the possibility of promoting local centers of excellence that are the crown jewels of this region. Another is deeper and Rossella Romeo explains it very clearly: "We, like WASP, began by accepting a challenge that could be defined as visionary: teaching blind people to become computer programmers. In WASP’s mission I see a lot in common with our own values ​​and aspirations: think big, do not stop at those which are considered to be the normal boundaries."

    The course has thus been set and not just for the blind but also for those with other disabilities: mobility impairments, cognitive problems, children with autism, elderly with dementia ... There already is a specific project that will use the Delta WASP 2040 3D pritner. It is called Clip4all and was selected among 10 winners of the Think for Social program by the Vodafone Foundation -> http://www.asphi.it/news/il-nostro-progetto-clip4all-tra-i-10-vincitori-del-bando-think-for-social-di-fondazione-vodafone/

    Within a few days of testing we have already created the first objects experimenting with conductive PLA to use with the Clip4all kit, in educational settings and for creating custom mice, in the most accessibile and creative way.

    Some tweet e and post

    From open source to Maker Economy and collective welfare

    “Collective intelligence gives a return when ideas circulate freely, nobody seize them and everybody help to develope them. In that way the passage from open source to maker economy and so to collective welfare can be realized.”
    Massimo Moretti, WASP’s founder, has no doubt: he choosed a long time ago the way of shared knowledge.
    “Ideas that circulate – continues Moretti - are several, they’re often magnificent, thrilling. The real frontier is to transform ideas in a shared project which is useful for everybody”

     Is it what is happening, for example, with new arm braces?
    “Exactly. The first design can be downloaded by everyone from Thingiverse and it was made by a young american designer, Andreas Bastian. He developed the concept of thermoforming PLA after having printed it plane.”

    Than, what happened?
    “The Bastian’s project has been discovered by +Lab, a center of research of Politecnico in Milan. +Lab was the first who had the intuition and the ability of grasping the potential of this project. And it properly emphasized it (http://www.thingiverse.com/thing:403001)”.

    What was the role of WASP in the partnership with Rizzoli?
    “ When the project arrived in our studio, some researcher from Rizzoli were there. They saw it and they found it interesting. Than they gave their contribute transforming it further, depending on the characteristics they needed in First Aid center.”

    What’s WASP contribute?
    “We gave to Rizzoli researchers the informations they needed to produce the arm braces in a fast and accurate way. We started a research for a bigger extruder and a greater amount of deposited filament: a dedicated printer for arm braces, which will allow to realize them in a few time and a low budget.”

    We can say that the development od this project had many partners involved.
    “Yes, it is exactly as you said and everybody must be quoted, because each one is a link in the chain from idea to solution. Nobody is the owner of the project, nobody can claim the intellectual property, but each one has his authorship.”

    Rizzoli’s willingness to insert itself in a procedure like this wasn’t so obvious.
    “An institution which is a medical center of excellence has the humilty of making full use of the shared knowledge that can be found on the net, and this is very important. It is important at the same way that these informations can be completed from the experience that only excellence institutes like Rizzoli can give.”

    What will be the next step with arm braces?
    “Rizzoli’s researchers said that they will share their work in open source, respecting all the parameters which are necessary for a collective evolution. We thank their researchers for the willingness to walk this path. When their work will be published on Thingiverse another hospital, maybe on the other side of the world, can give a contribute itself and make another step towards sharing knowledge.”

    You always insist on this word: sharing.
    “The kind of knowledge which generate welfare can’t be private.
    Too many companies with a great economic power develop technologies which they patent and in that way they make it inaccessible for most of people. When advanced knowledge will connect with shared knowledge it will be a spontaneous blooming of accessible practices, which will evolve through the collectivity in several ways, it will be impossible to patent it or anticipate it. A common benefit which can generate not only an healty society but also jobs, starting from common people.” 

    A few time ago these systems were watertight.
    “ It’s true. The world of ‘conventional research’ couldn’t get in contact with open source world, for an image problem. These patterns are breaking. Right now other things matter: true things, working and functional things.

    What’s the new approach which guide the technological evolution?
    “The concept is making things, concretely. Making with what you have, with the shared knowledge, the evolution which grows from the below. The maximum return with the minimum cost”

    Is patent time finished?
    “The concept that it’s important to spread is that nobody is the owner of this knowledge, nobody can claim the property. The sharing is the way to avoid patents and appropriations. Nobody can patent these informations because they have been shared, but everybody can use them.

    What are the prospects?
    “This new approach gives us wishes for a better world, where everybody works for a collective purpose. Everybody will have the opportunity to access to technologies that improve the quality of life, even without great financial possibilities.”

    Maurizio Andreoli

    Prova di sostituzione cranica con tecnologia FFF 2005 stampata con stampante 3d autoprodotta
    Prova di sostituzione cranica con tecnologia FFF stampata con stampante 3d autoprodotta 2005

    IMG_9394Porcellana stampata 3d e cotta con porosità controllata 2014

    WASP collaborates with Rizzoli's Orthopedic Institute



    Lowering the cost of custom tutors. Revolutionary cranial implants.

    The partnership between WASP and the Rizzoli Orthopedic Institute


    Tutors for to make First Aid centers more functional, whose cost is drastically reduced, almost entirely eliminated. In the future, cranial implants that almost entirely reproduce the skull’s characteristics, with the goal of facilitating bone regeneration and favoring an extraordinary bio-integration. This is possible through the adoption of world leading 3D printing technology in the medical field.

    The use of digital manufacturing in the health sector can radically modify patient care, making it economically accessible to all and implementing personalized therapies. The collaboration between WASP, a leading company in the 3D printing sector, and the Banca delle Cellule e del Tessuto Muscoloscheletrico (Bank of Cells and Muscular-Skeletal Tissue), of the Emilia Romagna Region, based within the Rizzoli Orthopedic Institute, is spawning projects to tear down walls that were considered untouchable until just a short time ago.

    The first tutors for First aid produced by 3D printing are ready and will begin the experimental phase at the Rizzoli Institute. They will be used to treat contusions, sprains and even fractures. At first they will be used for the wrist area and they will be made of PLA, with a cost of about 2 euro instead of the current 30 euro. Furthermore they are perforated for transpiration, while also allowing electro-stimulation to favor the healing process. After the wrist the project is set to move on to other body parts, starting from the elbow and the knee.

    Another ambitious and revolutionary project is related to the possibility of producing replacements for the cranial bone, directly from the patient’s CT scan data, using 3D printing. These will be 3D dowels of the same size as the missing bone parts, of which they will have to accurately mimic the anatomy and physiology. The goal is to facilitate an unprecedented bone regeneration. We are completing the development, testing and standardization phase. Within a few months we expect that the first prototypes will become available and that the first implants on patients may take place as early as 2016.

    The partnership between a research institutions and a local structure is made possible in part through projects financed by the Emilia Romagna Region.


    3D printed tutors for First Aid Centres

    3D printed tutors are employed in Rizzoli’s First Aid center. Tutors are printed in three different sizes, after that they’re shaped on the patient’s wrist. Massimo Moretti, WASP’s founder, affirms “we’re developing 3D printers with bigger sizes and bigger nozzles. It will be possible – thanks to the addiction of several dimensional parameter or the patient hand’s scan, to print tailored tutors in a very short time: 10-20 minutes. In that way there will be the chance to operate live on the place, depending on the situations”.

    To develope tutors we started from a prototype which was studied by PiuLab, an internal laboratory of Politecnico in Milan which collaborate with WASP in research. The choice of using PLA is because it is a thermoplastic material derivative of corn which is extruded at the temperature of 180°, but it is already malleable at 60°. The tutor is printed as it was flat, than it is heated and shaped according to the patient necessity and it is cooled down to keep the prearranged form.

    Heal-shaped tutors are not new in the First Aid field. The real news is 3D print, which allows to reduce costs till 90%. Moreover, bandaging the patient is no longer needed. The structure is particulary resistant, malleable for the different needs and pierceable, so it consents transpiration.

    Rizzoli’s First Aid centre staff has been indispensable for the developement of the project: we needed the advices of somebody who is near to the patients everyday.

    Some revisions were made during construction, just like the integration of three external lines that can be cut with scissors, to make the tutors adaptable to every kind of wrist. These lines are in the palm of the hand under the fingers, around the toe base and in the closure point, in the foreharm. The closure is made by self-adjustable strings. The chance of realizing tailored tutors will make the cut lines no longer needed.

    Another evolution is represented by the chance of a double material print, with a normal PLA and an electrical conductive one. This will permit to distribute electrons in the tutor’s structure, in that way it is possible to accomplish a tens, an electro stimulation or to create electromagnetic fields wich accelerate the healing process in case of fracture.



    tutori4 (1)


    Cranial substitutes

    Cranial substitutes which reproduce the original structure in three layers: two which have resistance and stability characteristics, one which facilitates regeneration. The skull cap, as time goes by, will be replaced by the patient bone in a spontaneous and physiological way, through an ossification process. It will be less and less a foreign body. As the director of the Rizzoli’s Cells and Musculo-skeletal tissue Bank, Pier Maria Fornasari, said to the magazine “Tecnica ospedaliera”,“in case of a serious cranial trauma the surgeon is often compelled to remove skull cup to consent to the brain to expand his volume. Once the brain return to the normal size the skull cup has to be refurbished. Until today there were three options: re-use the original cranial bone which can be washed and disinfected; otherwise it can be used an hydrioxopatite cranial box, it is a fragile material which forces the patient to be very careful for the rest of his life; another chance is to implant a plastic cranial box which is not be assorbed. These techniques lack is that they are made by a single layer, our cranial box is made by three layers instead.

    The innovative idea is to produce, directly from patient TAC, a substituite of the missing part of the cranial box made by a 3D printer. It isn’t only a substitute which has the perfect sizes of the missing parts but also the complete respect of the human anatomy with the reproduction of the three layers: one is external and rigid like the cortical bone, the one in the middle is made by a spongy tissue and the internalone is rigid cortical bone again.

    The research is currently focused about the material choice and the layng down tecnique. For the external parts will be used rigid and resistant materials which can be assorbed by the body, just like caprolactone. For the internal material it will may used hidrioxopatite, the aim is to make the rigeneration process start from here.

    The ossification process will be facilitate from a piece of the cortical part, so the zone which is in contact with the scalp, to simplify the insertion of blood-vessel.

    There already is a contact with several neurosurgery equipes to launch a partnership and pass to a pre-clinical and clinical sperimentation.

    More than a FabLab which prints cranial boxes for all the hospitals the project aim at a process that can be transfered in each clinical structure. In the future, the missing part of the cranial box will be directly printed in the operation room.

    The social impact of a project like this is huge. The prothesis that are used today cost thousand of euros and one day it would be possible to produce them just with an hundred euros. It will be possible to operate not only in italians hospitals but in war zone too, where these kind of problem are a daily issue.


    An Exceptional 3D-Printed Prosthesis

    There are certain applications of our 3D printers that inspire us and give our work meaning. Marco Avaro’s smile, the enthusiasm he exudes, and his desire to develop technology to make others’ lives better, have brightened our days. We are very fortunate to collaborate with Marco in his work. We discovered that it is now possible to create a high-quality, orthopedic prosthesis rapidly, thanks to 3D printing technology. This Friulian biomedical engineer has demonstrated that with a brand-new Delta WASP 2040, he is already able to make two prostheses a day.

    Avaro bought a Delta 2040 and was immediately pleased. The revelation that he could print a prosthesis socket of an excellent quality, was the turning point for Avaro. In his own words, “The printer made the difference. It enabled me to fabricate large pieces, even those larger than 40 centimeters, with just one print. The quality is so high, that it does not need to be treated before millwork. The printer is fast and the design of the printer allows me to consistently produce even exceedingly thin surfaces. The advantages are many. If you take degenerative diseases, for example, the geometries become particularly difficult since there are many asymmetries. Nonetheless, with this technology it is possible to treat a wide range of cases without any difficulties.”

    Since November 2014, when Avaro bought the Delta WASP, he has fabricated thirty prostheses. “Just to be clear,” says the engineer, “”I haven’t invented anything. I just applied the 3D printing technology. It is the printer that provides the practically perfect quality of the products. And it is very competitively priced, as well.”

    As Avaro stated above, the volume of the printer is definitely ample and permits the production of a socket that is both durable and light. This results from strong cohesion between print layers. This also translates into a number of other advantages. “This allows me to print hollow sockets, without having to worry about the acrylic resin filling the interior of the print,” explains Avaro, “Furthermore, there isn’t deformation while the prints are processed.”

    FEM (finite element method) modeling has revealed that the forces between technical materials (such as the resin or carbon fiber that Avaro also uses in his prostheses*) are spread evenly, something that becomes impossible if the acrylic resin spills into the prosthesis’ interior. The infiltration of the resin causes irregular variations in the rigidity, such that the prosthesis can be structurally compromised and fare poorly when exposed to cycles of alternating load (fatigue, or more simply put, continued usage.)

    “The prints made with the Delta WASP 2040 have brilliantly exceeded the mechanical and computational tests [I’ve subjected it to.] This provides the opportunity to make a structure that is strong and considerably lighter,” tells Avaro.


    If that’s not enough, there are also advantages from an aesthetic perspective, an aspect which is fundamentally important for the people who rely on it daily. It is possible to polish the prosthesis until it shines like a mirror, using particular resins and lacquers. Additionally, since each prosthesis is custom-made, they are more comfortable to wear.

    “The machine is fast,” reaffirms Avaro, “For a tibial prosthesis, it previously took me eight hours, and now it doesn’t even take two. I create prostheses for mountain climbers and cross country runners. And I’m always greeted with an immense thankfulness. When I finish the prosthesis, I deliver them and there is never a need to make any corrections. The clients’ physical therapists are amazed by what we do. In conclusion: my collaboration with WASP has changed my life.”


    The Del Bene orthopedic lab is situated on Rossetti Street, Trieste.
    The prosthesis production center is located in Azzano Decimo (Pordenone).
    WASP is located in Massa Lombarda (Ravenna)

    For more info feel free to contact us at: Marco Avaro 328 2968322; marcoavaro@gmail.com.