Recycled 3D-Printed Orthosis for Clubfoot Treatment

We (YEHALABS) are proud to announce a groundbreaking achievement that bridges sustainability, healthcare innovation, and accessibility. Our latest project marks a major step forward in utilizing eco-friendly materials and advanced 3D printing technologies to create impactful medical solutions for underserved communities.

Project Overview

We have successfully developed a cost-effective, 3D-printed Foot Abduction Orthosis (FAO) for the treatment of infant clubfoot, particularly addressing challenges faced in resource-constrained regions like Ethiopia. What sets this innovation apart is the use of recycled PET plastic—an environmentally responsible material that supports both sustainability and affordability in healthcare.

Using SolidWorks CAD software, our engineers optimized the FAO design to minimize material consumption while ensuring strength, flexibility, precision, and safety. The brace features:

• Adjustable abduction angles and dorsiflexion
• Customizable foot width for comfort and proper fit
• Durable and lightweight design, perfect for infant care

Why Recycled PET?

• Environmental Impact: Reduces plastic waste and promotes a circular economy
• Affordability: Lowers production costs, making orthotic devices more accessible
• Performance: Provides strength, durability, and flexibility for effective treatment

Cost and Impact

Our innovative approach brings the production cost to approximately $5.25 per unit, making it vastly more affordable than traditional commercial options. By repurposing plastic waste into life-changing medical devices, we are contributing to a cleaner planet and expanding healthcare access for families in need.

Over the past year and a half, we have collected around 430 kilograms of plastic waste and transformed it into valuable crafts and medical devices—helping keep the environment clean, creating job opportunities, and improving community health.

We believe the future of medical devices lies in combining technological excellence with environmental responsibility. Our work aims to inspire broader developments in sustainable healthcare innovation, 3D printing applications, and green technology integration across industries.

Recognition

We are honored that our work has been featured on MedDiscoveries.org, showcasing the real-world potential of 3D printing for healthcare transformation.

Acknowledgments

We extend our deepest gratitude to our incredible team of engineers, medical experts, and innovators whose dedication and passion have made this project a reality. Your expertise continues to drive meaningful change.