eng Oriental Scientific Publishing Company Biomedical and Pharmacology Journal 0974-6242 2026-07-15 19 3 72668 article Bethanney Janney J 1 Hari Krishnan Gurumurthy 2 Sindu Divakaran 1 Sudhakar Tukkaram 1 Mohadass Ganapathy 3 Vinod Srinivasan 6 Department of Biomedical Engineering, Sathyabama Institute of Science and Technology, Chennai, India. Department of Electrical and Electronics Engineering, School of Engineering, Mohan Babu University, Tirupati, India. Department of Biomedical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Saveetha University, Chennai, India Department of Electrical and Electronics Engineering, Jerusalem College of Engineering, Chennai, India Adolescent Idiopathic Scoliosis (AIS) typically requires non-surgical management through orthotic braces, which often present issues related to patient discomfort, limited compliance, and traditional manufacturing constraints. This study proposes an advanced methodology employing Computer-Aided Design and Computer-Aided Manufacturing (CAD/CAM) technology alongside Three-Dimensional Printing Technology (3DPT) to create highly customised braces specifically tailored to individual patient anatomy. Utilising polyethene terephthalate glycol (PETG) filament, braces are designed considering factors such as comfort, lightness, mechanical strength, and environmental sustainability. Patient-specific data obtained through detailed three-dimensional imaging and curvature analysis ensures precise anatomical conformity and effective spinal correction. Comparative analysis demonstrates substantial improvements over conventional brace fabrication, including reduced manufacturing time by approximately one-third, enhanced comfort, and increased patient compliance. The methodology integrates high-resolution CT imaging, Mimics-based segmentation, Materialise 3-Matic curvature mapping, Siemens NX CAD design, and ALPI V4 FDM additive manufacturing. Force Sensing Resistor (FSR) sensors embedded at corrective pressure zones provide real-time feedback, enabling iterative design refinement and improved clinical outcomes. Quantitative results confirm a ~65% reduction in production time, enhanced inter-operator reproducibility, and superior patient compliance scores compared to conventional plaster-cast braces. This research underscores the significant benefits of integrating advanced digital modeling techniques and additive manufacturing for improving therapeutic outcomes in AIS management. https://biomedpharmajournal.org/vol19no3/advanced-cad-cam-based-customisation-of-scoliosis-braces-using-patient-specific-data-and-additive-manufacturing/ Adolescent Idiopathic Scoliosis CAD/CAM technology Customised Brace Design   Force Sensing Resistors 3D Printing Patient-Specific Orthoses PETG filament Spinal Deformity Management