Sustainable orthopaedic solutions with AI-driven design and 3D printing for patient-specific CARE

3DCARE proposes a pioneering framework that transforms orthopaedic device manufacturing through the convergence of Artificial Intelligence (AI), Additive Manufacturing (AM), and advanced material science. By championing a sustainable, patient-centric approach, the project integrates novel computational methods, material innovation, and cutting-edge manufacturing technologies to revolutionize orthopaedic care. Central to the 3DCARE paradigm is an AI-enhanced design and optimization pipeline that enables rapid, precise customization of implants tailored to individual patient anatomies and clinical needs. This is further augmented by Topology Optimization (TO) algorithms and data-driven predictive models, which optimize structural integrity and performance while minimizing material usage and waste. The project emphasizes the development of 3D-printed raw materials—engineered from recycled inputs and tailored with additives to achieve superior mechanical and functional properties—establishing a new standard for eco-friendly, high-performance orthopaedic devices. Leveraging multi-material additive manufacturing techniques, 3DCARE produces complex, multifunctional structures that meet stringent biomechanical and environmental requirements.3DCARE’s multidisciplinary framework integrates advanced methodologies such as bioprinting, digital twins, and lifecycle analysis (LCA) to enhance design precision, streamline production processes, and minimize environmental impact. By fostering inclusivity, sustainability, and gender equity, the project ensures orthopaedic solutions address the diverse needs of all demographic groups. Through structured training, secondments, and stakeholder engagement, 3DCARE also equips researchers and professionals with cutting-edge skills, driving innovation in sustainable healthcare manufacturing. Aligned with the MSCA Green Charter and EU priorities, 3DCARE sets a new benchmark in sustainable orthopaedic manufacturing, offering transformative sol