This paper investigates the viability of using digital technologies, including 3D laser scanning, reverse engineering techniques and additive manufacturing in order to create bespoke, on demand, customised accessories through re-usable materials to enforce a circular design approach. Crutch users with arthritis are identified as a patient user group who's needs are not met by current solutions.We identified a remote data collection workflow to capture hand grip profiles, followed by a digital workflow resulting in an additively manufacturable customised product. Threedimensional laser scanning technology captured digital grip profiles which were manipulated in computer aided design (CAD) software to produce a customised hand grip digital file. The prototype was fabricated using Fused Filament Fabrication technology.We demonstrate that fused filament fabrication, a type of additive manufacturing technology, is an appropriate fabrication method to provide a bespoke and rapidly manufactured low-cost solution; the total timeframe to complete digital scanning and file creation is approximately 20 minutes. Additive manufacturing can be leveraged 24/7 with the customised hand grip rapidly fabricated within ~10 hours, with only material costs of £4.92/~US$6.15/~€5.65. To our knowledge, this study is the first to discuss using fused filament fabrication to fabricate customised daily living aids.Highlights: Fused Filament Fabrication combined with three-dimensional scanning provides a low-cost solution for customised daily living aids. Utilising additive manufacturing creates unexplored opportunities for advanced customisation.

Severe acute respiratory syndrome coronavirus 2, a novel coronavirus, caused global disruption specifically in linear supply chains. Increased demand for already disrupted services led to a global shortage of medical equipment and personal protective equipment. Use of additive manufacturing (AM) processes by the manufacturing community has shown great innovation, agility and flexibility to fill supply chain gaps and meet shortfalls. In the context of contingency reaction to a global healthcare emergency, decisions have had to be made quickly, in some cases bypassing device safety regulations. This concentrated and spontaneous use of AM has highlighted the challenges and risks of such innovation, which we discuss in relation to the UK’s current regulatory landscape. We have discussed lessons learned and the potential future impact upon wider use of AM in healthcare.

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