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Continuous recycling of 3D-printed orthopedic corsets

27.11.2023

With the introduction of 3D printing technology, orthopedic corsets have become a popular production method due to their numerous patient benefits. Create it REAL is among the technology leaders in this field, having developed a corset solution that allows for printing rigid and flexible zones in the same corset. However, as the lifespan of these custom-fitted corsets is limited to just a few years or even months, Create it REAL is now taking the next natural step by exploring the sustainability of these devices. The orthopedic corsets are produced from polypropylene, which may be suitable for recycling, but Create it REAL must learn about continuous material recycling.

Image: Manufacture of 3D-printed orthopedic corset. Right below in white letters: "Create it REAL"; Copyright: Create it REAL

Create it REAL is one of the technology leaders in 3D printing technology and shows new results and methods in the field of orthopaedic corsets.

It is the objective behind the TRACKY project founded by the DREAM program, part of the European Union Eurocluster initiative. Learn more about the Euroclusters https://clustercollaboration.eu/euroclusters.

Digital Resilient Europe for Advanced Manufacturing

TRACKY is part of DREAM, which stands for Digital Resilient Europe for Advanced Manufacturing, whose objective is to reinforce the European digital ecosystem applied to manufacturing. In other words, the projects have to support the transition to a green and digital economy and, at the same time, establish and maintain partnerships between companies at the EU level. 


Production of orthopedic corset based on marked recycled material

TRACKY, an initiative in sustainable manufacturing, has unveiled its project to transform the orthopedic corset industry. The primary goal of TRACKY is to demonstrate the viability of a circular economy business model centered around orthopedic corsets, contributing to the management of resources more sustainably. The company aims to transform the orthopedic corset industry, promoting sustainability and innovation to benefit patients, healthcare, and the environment. In this ambition, they have outlined specific project objectives:

  • Recycling 3D printing filament: The project seeks to produce high-quality 3D printing filament from old orthopedic corset parts, ensuring the material's integrity even through multiple recycling cycles.
  • Developing a tracking system: TRACKY is developing a tracking system that collects essential information about the material, including its stage of recycling and material type. This data will be seamlessly integrated into the 3D file.
  • Quality production monitoring: The project involves monitoring production quality across multiple sites, ensuring the recycled materials meet the necessary standards.
  • Demonstrating printability: TRACKY aims to showcase the feasibility of using recycled materials in 3D printing, particularly with Fuse Deposition Modelling (FDM), and validate their mechanical properties.
  • End-user benefits: The project intends to demonstrate to end-users the advantages of using recycled materials from both cost and resource perspectives. This involves starting from an old corset part, recycling it into a new filament, and automatically modifying the 3D file for seamless incorporation into the final product.
Image: Several white orthopaedic corsets next to each other; Copyright: Create it REAL

The orthopaedic corsets are made from polypropylene, which is suitable for recycling.

The founder and CTO of Create it REAL, Jeremie Gay, explains: "This is entirely new ground. Until now, we have only been recycling polypropylene one time. We are particularly interested in how it behaves after the fourth, fifth, or many more times reuses. Do we need to auto-adjust how we print to maintain the material quality and maximize the times it can be reused? Can we reuse it forever under the right conditions? Can we track those conditions? This is what we want to answer with the TRACKY project".

The expected outcome


TRACKY project's success depends on effectively tracking materials and integrating vital data into 3D files. This streamlines production while maintaining top-quality standards, benefiting orthopedic patients and the medical sector. Additionally, the project aligns with digital technologies like IoT and System Integration, primarily targeting the medical and potentially other sectors, depending on material recovery practices.
Image: Six wooden cubes placed on top of each other with labels in the spirit of recycling. The top cube is labeled "Zero waste"; Copyright: Create it REAL

TRACKY is an initiative for sustainable production and focuses, among other things, on demonstrating the viability of a circular economy business model for orthopaedic corsets.

TRACKY expects key outcomes: 

  • Demonstrating cost-effective corset recycling
  • Optimizing material supply chains and reducing waste
  • Environmental impact assessment with Life Cycle Assessment

Create it REAL has established Key Performance Indicators (KPIs) to ensure material tracking and reduced reliance on entirely new materials in production. The project is started and runs until the end of May 2024 and is led by founder and CTO Jeremie Gay, Create it REAL.


REHACARE.com; Source: Create it REAL
Gif animation: REHACARE 2025 from 17 to 20 September 2025 in Düsseldorf/Germany, linked to "More information about the Trade Fair"

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