Boundless Biomechanical Bracing

09/08/2025

While we were not at AOPA this year, it is great to see all the posts of everyone enjoying the conference and how far 3D printing in O&P has come. There is a real buzz and support around the industry and how we can best support our clients.

Over the past several years, we’ve collected extensive feedback from patients comparing traditional ankle-foot orthoses (AFOs) with 3D-printed AFOs.

When we compiled the most common comments a clear theme emerged:
👍 Comfort, lightweight, improved fit, thinner and better aesthetics consistently stand out to patients as benefits of our 3D-printed devices.

👎 Some of the negatives were that initial designs were too tight, highlighting the importance of the digital modification process for clinicians and transferring plaster knowledge to the digital space.

We’re excited to be part of this movement, pushing the boundaries of what’s possible in orthotic care.

08/28/2025

Here’s a behind-the-scenes look of our manufacturing team extracting parts fresh from our Multi Jet Fusion 4200 (MJF) printer.

Once out of the build, every device is sand blasted to remove residual powder and maintain a consistent surface finish. They can then be finished in one of our two standard options:
⚫ Deep Dye Black – a standard finish that hides scratches, nicks, and day-to-day wear while giving a sleek look
⚪ Raw Gray – the natural MJF finish, perfect for prototyping, parts that may be components of an assembly, functional surface finishes straight from the printer

These finishing options are designed to balance durability, aesthetics, and clinical performance, so every device is patient-ready.

08/21/2025

Can you grind into 3D Printed AFOs???

Yes, but it's different.....

Yes, it's still common practice to grind back trimlines, trim back a toeplate, and fine-tune material during fitting. But here’s some key differences from traditional thermoplastics like copoly or polypro:

👉 Use a variable-speed trautman
👉 Slow it down....much slower than you’re used to
👉 Why? Going too fast creates extra heat, making the material ‘gummy’ and harder to work with

(Yes, this clip is sped up… but in reality, slowing down is your best friend here.)

Raw parts are grey, but when ground in to, the area turns black. That’s one reason we offer deep dye black services. It hides nicks, dings, and scratches that can happen before fitting or during normal wear.

If you’re curious about digital adoption in orthotics and prosthetics, go to https://www.linkedin.com/showcase/108165161 and tap that follow button ....we’re just getting started. What's been your experience working with MJF PA12?

08/18/2025

🚀 Sneak Peek – Boundless Digital Technologies is here! From the team at Boundless Biomechanical Bracing, we’re opening the doors to a new space dedicated to digital technologies in O&P.

Give our new page a follow if you are interesting in seeing....

🎓 Education content – Deep dives into material properties, grinding, heating & flaring techniques, scanning workflows, and design considerations for additive manufacturing. We will look at the differences in FDM, SLS, or MJF 3D printing, what applications are right for which technology and more.

🛠 Product Features – Step-by-step guides on uploading files and placing orders for Hinged, Rigid, and ESR AFOs, plus an inside look at the unique features of each device. We’ll share case studies, research findings, and publications that back our designs.

🔍 Behind the Scenes – See what else we’re creating with Multi Jet Fusion technology, and how our devices are brought to life with advanced digital tools.

💬 Discussion – Honest conversations about the real challenges of adopting 3D printing in O&P. After 7 years navigating the ups, downs, and everything in between, we’re here to share what’s worked, what hasn’t, and what we’re still learning—so you can fast-track your own digital journey.

This is more than a new page—it’s a place for our colleagues in the O&P community to learn, connect, and push the boundaries of what’s possible.

Follow Boundless Digital Technologies and join us on this exciting...and challenging journey! LINK - https://www.linkedin.com/showcase/108165161

04/23/2025

Please check out the opportunity below and attend this ISPO ONLINE WEBINAR if you are able to.

Dan looks forward to sharing our experiences from the perspective of a clinical practice in O&P.

📣 Upcoming ISPO Webinar – 3D Printing in P&O: Opportunities vs. Challenges

🗓️ May 28, 2025

⏰ 15:00 CET | 9:00 AM EDT

📍 Live on Zoom: https://us02web.zoom.us/webinar/register/WN_qFsRcD1pSEmt9JKeXlx2SQ

We invite you to a thought-provoking global webinar focused on the evolving role of 3D printing in prosthetics and orthotics.

💡 What to Expect:

✅ Real-world insights from experienced professionals

✅ Case studies and practical applications of 3D printing

✅ A transparent discussion of challenges and limitations

✅ Live Q&A and open dialogue with the audience

🎙️ Expert Panel Includes:

• Ahmad Najwa – Printer settings & scanning

• Brent Wright – Materials & structural strength

• Hélène Victor – Software: generic vs specialized

• Hugh Sheridan – Post-processing & field experience

• Dan Blocka – Key challenges in O&P

• Ajaaz Ahmed Zargar. – Lessons from failures

• Abder Banoune – NGO experience & implementation

🧑‍⚖️ Moderated by: Arezoo Eshraghi & Youssef Salam

📌 Registration is FREE for ISPO members (USD 15 for non-members)

👉 Spots are limited – register now!


🔗 https://us02web.zoom.us/webinar/register/WN_qFsRcD1pSEmt9JKeXlx2SQ

📷 Don’t forget to save the date and share this with your network!

The IMEA CPO

04/08/2025

We’re Hiring!

Boundless Biomechanical Bracing is excited to announce a new opportunity within our practice: we are looking for a dedicated and motivated Orthotic Assistant to join our team on a one-year renewable contract.

In this role, you’ll work closely with our Registered Orthotic Technicians and Certified Orthotists, supporting various clinical, technical, and administrative tasks.

This is an excellent opportunity for individuals with a background or strong interest in Health Sciences or Engineering Technology who are eager to gain hands-on experience in the Orthotics and Prosthetics profession.

At Boundless, we have over 37 years of national and international leadership in providing client-focused orthotic care. We specialize in the evaluation, fabrication, and delivery of custom orthotic solutions that enhance mobility and improve lives.

If you know someone who might be a great fit, please feel free to share this post or tag them below. We’d love to connect with passionate individuals ready to make a difference in our practice!

LINK TO POST: https://cocincon.sharepoint.com/:b:/g/EReuFKiQz0xPnDLtFFCI464BXSJ-Wut3gSLC_WiFxLp_Dw?e=qzDgsE

NOTE: This also posted on our Boundless Biomechanical Bracing LinkedIn page.

01/09/2025

We are excited to announce an opening for a Junior CAD Designer! If you know someone who would be a great fit for this role, please share this opportunity with them. SEE LINK TO POSTING BELOW.

🔹 Position: Junior CAD Designer 🔹 Industry: Orthotics & Prosthetics

Help us spread the word and find the perfect candidate to join our innovative team!

Posted 4:53:30 PM. Start Date: February 2025Salary: Negotiable, based on experience and educationPosition…See this and similar jobs on LinkedIn.

10/24/2024

We are again very happy to support the ISPO International GEM meeting here at the Baylor College of Medicine. This the fourth time we have been a sponsor of this terrific event along with our founder Dan Blocka being part of the organizing committee since it’s inception.

🌟 Exciting Times at !

Yesterday marked the first day of hashtag , and it was fantastic! 🎉 Check out some of the pictures from our inspiring sessions and engaging discussions.

Today, we're kicking off bright and early at 8:30 AM, with a packed agenda featuring three sessions: the Symposia Session, NCOPE's session, and the ISPO Accreditation session.

Looking forward to another day of learning, networking, and innovation!

09/19/2024

We are part of an incredible, not well known and under recognized profession. My colleagues across this country and the world are amazing people who dedicate much of their lives to those we serve. 😀

Today is the day! 🎉

We are thrilled to announce today as the first annual National Orthotics and Prosthetics Day!

This day acknowledges and celebrates orthotists, prosthetists, and technicians across the nation, and the patients who's lives are positively impacted by the skill and care of these professionals.

Join us in celebrating this momentous day for the O&P community by sharing your story as a professional or patient, using the hashtags and

03/01/2024

Boundless Biomechanical Bracing is very proud and excited to announce that in partnership with our colleagues at Holland Bloorview Kids Rehabilitation Hospital, a significant Canadian Institutes of Health Research (CIHR) grant has been awarded for a project seeking to collect much needed data to support the inevitable transition of the fabrication and delivery of Ankle-Foot Orthoses (AFOs) by comparing digitally and traditionally produced AFOs through a feasibility randomized control trial. The research team, based out of Holland Bloorview Kids Rehabilitation Hospital and Boundless Biomechanical Bracing includes orthotists, clinicians, engineers, physiotherapists, and researchers. It is anticipated this work will contribute to more efficient and patient-friendly orthotic interventions.

To be involved directly in securing a grant from the CIHR, is a great achievement for a practise like ours in the Orthotic and Prosthetic profession. With this, it's important to acknowledge the great work & effort made by our team to make this a success, especially both Anne Whitney & Thomas Burton, MASc for their input given throughout the process.

https://discover.bme.utoronto.ca/four-biomedical-engineering-faculty-members-secure-cihr-funding-for-research-projects/

Four Biomedical Engineering Faculty Members Secure CIHR Funding for Research ProjectsQin Dai News February 1, 2024 2 min read Share Four esteemed faculty members from the Institute of Biomedical Engineering (BME) at the University of Toronto have successfully secured funding from the Canadian Instit...