A Belgian orthotic company transforms its production pipeline through the Start AI Brussels program, turning hours of skilled work into minutes of automated precision powered by artificial intelligence.
In the precision-driven world of custom orthotics, every millimeter matters. For patients requiring facial masks for medical treatment, the fit must be perfect. Too loose and it's ineffective, too tight and it's uncomfortable. This is the daily challenge that Spentys, a Belgian company specializing in custom orthoses, has been tackling with their innovative 3D scanning and printing approach.
The company has already proven their expertise in creating precision devices for high-stakes situations; from protective facial masks for professional footballers recovering from injuries to custom orthoses for athletes. But until recently, one critical bottleneck remained: the time-intensive process of manually designing each facial mask from 3D scan data. That changed when Spentys partnered with SustAIn.brussels to start the Start AI Brussels program and expert AI consultancy Sagacify to develop an AI-powered solution that promises to transform not just their workflow, but the entire custom medical device manufacturing industry.
The Challenge: When Expertise Becomes a Bottleneck
Spentys had already established itself as an innovator in the orthotic space, using portable 3D scanners to capture precise measurements and create custom devices tailored to each patient's unique anatomy. Whether creating protective masks for injured footballers or medical devices for patients, their approach offered significant advantages over traditional molding techniques: faster capture, better accuracy, and improved patient comfort.
However, the process from scan to finished mask still required considerable manual intervention. Skilled technicians needed to:
- Interpret raw 3D scan data using specialized knowledge
- Identify the optimal mask contour for each individual face shape
- Adjust the design for comfort and breathability
- Prepare the final model for 3D printing
This manual process, while effective, created several challenges:
- Time constraints: Each mask took hours of specialized work to design
- Cost implications: High labor requirements made scaling difficult
- Consistency issues: Results varied depending on the technician's experience
- Patient wait times: Longer turnaround times delayed treatment
The vision was clear: reduce turnaround times significantly, lower production costs without compromising quality, and create a solution that integrated seamlessly with existing tools. But could artificial intelligence replicate the specialized expertise that orthotists develop over years of training?
Enter Start AI Brussels: From Vision to Reality
The Start AI Brussels program, guided by sustAIn.brussels, provides exactly the support innovative SMEs, Start-ups and Scale-ups need to explore AI applications. The program doesn't just offer funding; it provides structured guidance, technical expertise, and a clear pathway from concept to working prototype.
For Spentys, this was the perfect opportunity to test their ambitious idea: could AI transform their scan-to-mask process from hours of manual work to minutes of automated precision?
The AI Solution: A Four-Stage Automated Pipeline
Working closely with Sagacify's technical team, Spentys co-developed an intelligent four-stage pipeline that transforms raw 3D facial scans into print-ready mask designs using computer vision and machine learning. Sagacify brought deep expertise in AI algorithms and 3D processing, while Spentys provided the orthotic domain knowledge essential for creating medically accurate devices.
Stage 1: Advanced Data Processing - The system processes 3D scan data using Sagacify's proprietary algorithms that can handle various input formats (LiDAR, photogrammetry, structured light scanning) while identifying and correcting common scanning artifacts.
Stage 2: AI-Powered Facial Analysis - Sagacify's computer vision models automatically detect 468 facial landmarks with sub-millimeter precision, applying biomechanical analysis to determine optimal mask positioning. The AI understands facial anatomy, breathing patterns, and pressure distribution zones.
Stage 3: Intelligent Mesh Optimization - The co-developed algorithms eliminate scan imperfections while preserving critical anatomical features. The system applies a precise 2mm respiratory offset, but intelligently varies this based on facial topology and intended use case.
Stage 4: Automated Design Generation - The final stage uses Sagacify's generative algorithms to add structural thickness, ventilation patterns, and personalization features while ensuring printability and mechanical integrity.
This automated approach eliminates the guesswork and variability of manual design while consistently producing results that meet or exceed traditional quality standards. The AI system, co-developed by Spentys and Sagacify, has learned to replicate the expertise that skilled technicians develop through years of experience, while Sagacify's algorithms ensure the technical precision needed for medical-grade devices.
Real Results: From Prototype to Production
The project culminated in a functional TRL 5 demonstrator, software with a minimal interface that proves the entire concept works in practice. The results speak for themselves:
- Speed: What once took hours now completes in minutes
- Consistency: Automated AI processes eliminate variability between operators
- Quality: AI-driven optimization often produces superior results to manual design
- Scalability: Production can increase without proportional increases in skilled labor
To validate the system, the Spentys-Sagacify team produced both video demonstrations and physical 3D-printed masks, proving that the AI-generated designs meet the same quality standards as manually created ones. The collaboration successfully demonstrated that Sagacify's AI algorithms could process Spentys' real-world orthotic requirements with the same precision that creates protective masks for professional footballers.
Beyond the Prototype: A Vision for the Future
While the current demonstrator already represents a significant breakthrough, Spentys and their partners see this as just the beginning. Future developments could include:
- Mobile integration: Smartphone-based scanning for in-clinic or even at-home measurement
- Enhanced personalization: Advanced texture mapping, colour options, and embedded patterns
- Expanded applications: Adapting the same principles to other orthotic devices
- Real-time feedback: AI-powered quality assessment during the scanning process
The vision extends to AI systems capable of serving thousands of personalized medical devices daily, each one optimized by artificial intelligence that continuously learns from successful designs.
The Broader Impact: A Model for AI Adoption
Spentys' success story represents more than just a technical achievement; it's a blueprint for how SMEs can successfully integrate AI into their operations. The project demonstrates several key success factors: clear problem definition rather than adopting AI for its own sake, expert partnership with Sagacify to provide the technical depth needed for complex 3D processing challenges, a structured approach through the Start AI Brussels program that provided framework and funding, and a practical focus on delivering a working solution rather than just a research exercise.
Transforming an Industry
The implications of Spentys' innovation extend far beyond their own operations. By proving that AI can automate complex, customized manufacturing processes, they're pioneering approaches that could transform the entire medical device industry.
For patients, this means faster access to precisely fitted devices. For clinicians, it means more efficient treatment workflows. For the industry, it demonstrates how AI can enable mass customization without sacrificing quality or significantly increasing costs.
As Spentys continues to refine their system and explore broader applications, they're positioning themselves at the forefront of a new era in orthotic manufacturing; one where the precision of custom fabrication meets the efficiency of automated production.
Ready to Transform Your Business?
Spentys' journey from manual processes to AI-powered automation shows what's possible when innovative companies partner with the right experts and programs. Start AI Brussels continues to support SMEs ready to explore how AI can transform their operations, providing the guidance, expertise, and funding needed to turn ambitious ideas into working solutions.
The future of manufacturing is increasingly automated, intelligent, and personalized. Companies like Spentys and Sagacify are showing the way forward, one perfectly fitted mask at a time. This AI breakthrough is just the beginning; their collaboration is just the start not the finish.
From Manual to Automated: How Spentys is Revolutionizing Facial Mask Manufacturing with AI