Design Engineer at Spentys — I build the computational systems that turn 3D body scans into individualised, manufacturable devices, from scan to production file.
I hold a B.A. in Materials & Nanotechnology Engineering from Politecnico di Milano, an M.A. in Product Design from ELISAVA Barcelona, and an M.C. in Parametric Design and Digital Fabrication from Controlmad.
Currently at Spentys in Brussels, I develop patient-specific orthopaedic devices from 3D body scans, automate computational workflows in Grasshopper/Rhino, and design new products from clinical brief to production file.
My edge is the overlap: I can evaluate a material at the molecular level, model it parametrically, and prototype it — then hand over a validated design file to manufacturing.
An articulated dynamic ankle-foot orthosis built as a system, not a model: one Grasshopper definition takes a leg scan and returns a print-ready, assembled device — shank, footplate, hinges and straps included.
Every patient gets a different scan, but the device still has to assemble: hinge axes must land on the anatomical joint, the footplate must meet the shank, the straps must clear both. Hand-modelling each one does not scale past a handful of patients.
Anatomical landmarks are extracted from the mesh, the base geometry is segmented, remeshed and offset to wall thickness, and every module then rebuilds itself against those references. Where stock components stopped, I wrote custom C# ones — and the whole definition ships as a configurator the team runs without opening Rhino.
A family of ankle-foot orthoses generated from the patient scan — rigid shell, hinged variant and a perforated night splint — where fit, stiffness and appearance are parameters of the same model.
An AFO supports the ankle through the gait cycle — but it is also worn all day, in public, often by children. Devices that fit badly or look clinical get left in the wardrobe, and a device nobody wears treats nobody.
The shell rebuilds itself on each scan, and its outer surface then doubles as a design canvas: graphics are UV-mapped onto the double-curved shell without distortion, and openings are placed where stiffness allows. Same geometry, same clinical function, a device the patient picks.
The shell is unrolled to a flat parameter space, the artwork is laid out on it, and the result is mapped back onto the double-curved surface. The print stays continuous across the curvature — no seams, no stretch at the ankle.
It is the same operation a knitted upper needs: a 2D pattern that has to land correctly on a 3D last.
A low-profile shell that controls the hindfoot while leaving the ankle free — the smallest device that still does the job, generated per patient.
Children with flexible flatfoot or low muscle tone need frontal-plane control of the hindfoot — but a full AFO blocks the ankle they still need to develop. Too much device is its own failure mode.
The shell wraps just above the malleoli and stops there. Trim lines, window openings and wall thickness are sliders on a scan-driven model, so a clinician's adjustment is a parameter change — not a remodel.
Patient-specific 3D-printed orthosis for infants with hip dysplasia (DDH) — a lightweight, parametric alternative to the traditional plaster spica cast.
Developmental dysplasia of the hip (DDH) affects 1–3% of infants. Treatment requires 3–6 months of continuous immobilisation — currently achieved with heavy plaster spica casts that are painful to fit, prevent diaper changes, and cannot be adjusted as the baby grows.
Hipcare is a parametrically designed, patient-specific PLA orthosis with variable-density lattice structures. It is 3D-printed per patient, softened at 50 °C for a precise fit, and features a clip system that allows diaper changes — all without removing the device.
Four years of parametric design and digital fabrication, on top of a materials engineering degree — and the programming to push past what the stock nodes do. I write the components I need, and increasingly I build with AI models in the loop.
