Case Study: Berretta Medical streamlines custom brace production with Materialise CO-AM

CO-AM Platform Connects BMI, Toolkit3D, and Extol to Enable Mass-Personalized O&P Medical Products

Berretta Medical (BMI), a family-owned orthopaedics and prosthetics manufacturer, needed a faster, more scalable way to produce bespoke patient braces. Their traditional molding and milling process was time-consuming, labor-intensive, and prone to manual errors, especially as they explored 3D printing to handle growing demand and production complexity.

Materialise implemented its CO-AM software platform to connect BMI, Toolkit3D, and Extol in one secure digital supply chain. The solution streamlined scan-to-print workflows, reduced manual file handling by up to 75%, cut design time to 20–30 minutes, and helped BMI save 5–10% in part costs while improving speed, accuracy, and scalability.

Berretta Medical

Nick Berretta

Business Development Lead and Owner