Orthotics manufacturers are increasingly embracing industrial 3D printing to build custom orthotics for their customers. Creating custom orthotic insoles using 3D printing technology involves a combination of digital foot scanning, design software, and 3D printing hardware. Compared to traditional methods of manufacturing orthotics, digital manufacturing of orthotics results in higher accuracy, quicker manufacturing times, and reduced labor.
Here's a guide to software providers and digital scanner manufacturers that are commonly used in the industry.
Steps to Create Custom Orthotic Insoles
Foot Scanning
Othorics manufacturers use a digital scanner to capture a detailed 3D image of the patient's foot. This image will serve as the basis for the custom insole design.
Modeling and Design
Once you have a scanned image of the patient's foot, import the scanned data into orthotics design software. Use the software to create a custom orthotic design that meets the patient's specific needs, including arch support, cushioning, and corrective features.
3D Printing
Once the design is finalized, send the model to a 3D printer. Choose the appropriate material for the insole, such as flexible polymers for comfort and support. Common materials include Nylon 12 and Nylon 11 for stiffer orthotics, and TPU (Thermoplastic polyurethane) for greater rebound and flexibility.
Post-Processing
After printing, some insoles may require post-processing, such as vapor smoothing to enhance material properties or adding top covers for additional comfort.
Fitting and Adjustment
Fit the 3D printed insoles to the patient and make any necessary adjustments for optimal comfort and functionality.
By combining accurate scanning technology with advanced design software, the creation of custom orthotic insoles becomes a precise and personalized process, with a quicker turnaround time and a more precise fit for the patient.
Digital Scanners for 3D Printed Orthotic Manufacturing
There are a variety of companies that specialize in creating digital scanning technology to produce 3-dimensional images of the foot. These range from small scanners that attach to your mobile device to stand-on scanners capable of diagnosing specific foot conditions. The companies listed below are some of the more popular options on the market, listed in no particular order.
Ellinvision
Overview: Elinvision specializes in high-precision 3D scanning technologies applicable to healthcare and orthotics. They provide advanced scanning solutions known for their accuracy in capturing detailed anatomical data, essential for designing customized orthotic solutions that meet individual patient needs.
Website: Elinvision
LutraCAD
Overview: LutraCAD scanners are advanced tools designed for capturing precise 3D images of the foot, essential for creating custom orthotic insoles. These scanners provide detailed measurements and accurate contours, ensuring a perfect fit for orthotics. Compatible with LutraCAD software, they streamline the workflow from scanning to design and production. The user-friendly interface and high-resolution scanning capabilities make LutraCAD scanners ideal for professionals seeking efficient and reliable solutions for orthotic manufacturing.
Top Products: LX500 Compact, LX800 Plus, LXL1800
Website: LutraCAD
pedCAT
Overview:The PedCAT 3D scanner, developed by CurveBeam, is a specialized imaging device designed for foot and ankle diagnostics. It uses cone beam computed tomography (CBCT) technology to produce high-resolution, 3D images of the foot, providing detailed views of bone structure and joint alignment. The PedCAT scans the foot while the patient is in a natural standing position, which enhances diagnostic accuracy.
Top Product: pedCAT
Website: Curvebeam AI
Scanpod 3D
Overview: Scanpod 3D specializes in developing high-resolution 3D scanning solutions tailored for orthotics and medical applications. The Scanpod 3D Scanner is known for its accuracy in capturing detailed foot anatomy, facilitating the creation of custom-fit orthotic insoles with precise measurements. Some of the scanners also have auto-landmarking, measuring, and diagnostic capabilities.
Top Products: XSOL and XPOD product lines
Website: Scanpod 3D
Volumental
Overview: Volumental specializes in creating 3D scanning solutions for footwear and orthotics, focusing on enhancing customer fitting experiences. Their 3D Foot Scanner uses computer vision and machine learning to create accurate 3D models of feet, facilitating the design and production of custom orthotic insoles.
Top Product: Volumental 3D Foot Scanner, Volumental online mobile foot scanning
Website: Volumental
Artec 3D
Overview: Artec 3D offers high-precision 3D scanning solutions renowned for their accuracy and versatility in capturing detailed foot anatomy. The Artec Eva is a handheld scanner ideal for capturing medium to large objects, while the Artec Space Spider excels in capturing intricate details with high resolution, making them suitable for orthotics design and production.
Top Products: Artec Eva, Artec Space Spider
Website: Artec 3D
Revopoint
Overview: Revopoint offers cost-effective and portable 3D scanning solutions suitable for medical applications, including orthotics. The Revopoint POP 3 Plus is designed for ease of use and affordability, making it accessible for professionals seeking accurate 3D scans of foot anatomy for orthotics design and manufacturing.
Top Product: POP 3 Plus
Website: Revopoint
Occipital Structure Sensor
Overview: Structure Sensor specializes in producing scanning technology which converts your mobile device to a 3D scanner. These scanners offer a cost-effective solution for capturing precise foot data, facilitating the creation of custom 3D-printed insoles. The Structure Sensor is widely adopted in the orthotics and prosthetics field.
Top Products: Structure Sensor 3, Structure SDK 3.0
Website: Structure.io
Apple iPhones and Orthotics Apps
Overview: The LIDAR cameras in newer iPhones and iPads create precise 3D scans of objects, including feet. For orthotics manufacturing, the LIDAR sensor emits light pulses that bounce off the foot, capturing detailed measurements and contours. This data is processed by specialized apps, transforming it into an accurate 3D model. One example is the Comb app, which converts the scans into orthotics models. Comb also provides a scanning fixture which helps create accurate 3D scans of the foot.
Website: Combscan
Design Software for 3D Printed Orthotic Manufacturing
There are various software options available that convert digital scans into designs for orthotic footwear suitable for 3D printing. Here are just a few of the many choices.
Fit360
Overview: Fit360 is a cutting-edge 3D scanning solution designed for creating custom orthotic insoles. Using advanced scanning technology, it captures precise foot measurements and contours, ensuring a perfect fit. Fit360's portable and user-friendly device quickly generates detailed 3D models of the foot, which are then used to design and manufacture personalized orthotic insoles with 3D printing technology. This technology enhances the comfort and effectiveness of orthotics by providing accurate data on foot structure and pressure distribution, leading to better support and alignment for users.
Website: https://fit360ltd.com/
Gespodo
Overview: Gespodo is a leading provider of 3D scanning and printing solutions for custom orthotic insoles. Utilizing advanced scanning technology, Gespodo captures accurate and detailed foot measurements, which are essential for designing tailored orthotics. Their system ensures a precise fit by analyzing foot structure and pressure points, resulting in insoles that offer superior support and comfort. Gespodo offers the Footscan 3D mobile scanning app with the FootCAD3D design software that designs custom footbeds based on teh scan.
Website: https://podo.gespodo.com/en/
Leopoly
Overview: Leopoly's LeoShape is a versatile 3D modeling and design software tailored for creating custom products, including orthotic insoles. It offers an intuitive interface that simplifies the process of designing personalized 3D models, making it accessible for users with varying levels of expertise. LeoShape's powerful customization tools allow for precise adjustments based on detailed foot scans, ensuring a perfect fit and enhanced comfort for orthotic insoles. The software supports integration with various 3D scanners and printers, streamlining the workflow from design to production.
Website: https://leopoly.com/leoshape/
LutraCAD
Overview: LutraCAD software is designed for creating custom orthotic insoles with precision and efficiency. It features advanced modeling tools that allow for detailed customization based on individual foot scans, ensuring a perfect fit. The software integrates seamlessly with various 3D scanners and printers, including their own line of scanners. LutraCAD's intuitive interface makes it accessible to both professionals and newcomers in the orthotics field.
Service Providers for 3D Printed Orthotic Manufacturing
Most orthotics companies outsource the manufacturing of their 3D-printed insoles to guarantee precision and the use of top-quality materials. By partnering with 3D printing service providers, these companies can access a broad selection of industrial-grade materials with superior material properties, without needing to invest in their own 3D printers. Additionally, 3D printing service providers are capable of mass production, delivering dozens or even hundreds of orthotics within days of ordering.
This collaborative approach not only enhances the quality of orthotic solutions but also accelerates the delivery of customized products to patients, ultimately improving their comfort and mobility.
3D Print your Orthotics Insoles with Tempus 3D
Partner with Tempus 3D for your orthotics digital manufacturing services. Tempus 3D has experience in manufacturing custom orthotics for the Canadian market, using industry-leading HP Multi Jet Fusion 3D printing technology. Offering experience, precision, and guaranteed quality, Tempus ensures your orthotics are manufactured on-time and on-spec.
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