ORTHOPEDIC MANUFACTURING IN UKRAINE DURING WARTIME: CURRENT STATE, CHALLENGES, AND PROSPECTS FOR CUSTOM ORTHOPEDIC FOOTWEAR PRODUCTION

Abstract

Purpose. The study analyzes the current state of orthopedic footwear manufacturing in Ukraine under conditions of full-scale war, with particular emphasis on the production of bespoke orthopedic footwear. It identifies the key challenges facing the sector and explores potential solutions through the adoption of advanced approaches and digital technologies. The research also investigates pathways for streamlining the design and manufacturing process of customized orthopedic footwear by integrating digital tools and effective collaboration formats with technical laboratories and specialized professionals, illustrated through a practical experimental case. Methods. An analytical review was conducted, including statistical data from rehabilitation centers and orthopedic enterprises, content analysis of regulatory documents and rehabilitation supply programs, as well as a comparative assessment of technologies and costs for manufacturing standard versus custom-made orthopedic footwear. A case study in the form of a practical experiment was undertaken, involving the design and production of orthopedic footwear tailored to the individual needs of a disabled serviceman, utilizing contemporary digital technologies. Results. Amid war and the sharp increase in demand for orthopedic devices, Ukraine’s orthopedic sector has faced a reduction in the number of operating enterprises due to destruction, alongside a shortage of skilled personnel caused by migration and limited educational programs. It was determined that only around 20 % of orthopedic-oriented enterprises in Ukraine produce footwear on a bespoke basis. A series of systemic problems were identified and analyzed, revealing barriers that hinder the sector’s performance and limit patient access to orthopedic products. Within the framework of the case study, adaptive boots were designed for use in the rehabilitative and post-rehabilitation phases of treatment for an injured serviceman. These models were developed in accordance with modern biomechanical principles and individualized last construction. The footwear was produced through a collaborative format involving a research and technical laboratory employing digital tools, a footwear manufacturing facility equipped with shoemaking machinery, and expert medical consultation. Scientific novelty. For the first time, a comprehensive analysis was carried out covering the technological, economic, and organizational aspects of enterprises specializing in the production of bespoke orthopedic footwear. A collaborative model was proposed, linking existing manufacturing facilities with orthopedic centers and research laboratories by introducing new stages into the production workflow, thereby enhancing the efficiency of custom orthopedic footwear manufacturing. A case study of the design and production process was conducted in a cross-structural collaboration format, demonstrated through the practical experiment of producing custom-made rehabilitation footwear for a patient recovering from injury. Practical significance. The analysis of the orthopedic footwear manufacturing sector revealed a set of problems that can be addressed through optimization of production algorithms, adoption of cutting-edge technologies, and engagement of skilled specialists. These measures will establish the foundation for a competitive and resilient sector capable of promptly responding to contemporary challenges and patient needs. The study provides recommendations for optimizing the production process of orthopedic footwear through the efficient use of existing manufacturing capacities, integration of external structures at preparatory stages, and application of digital equipment to refine production workflows and improve the quality of orthopedic products.