3D printed orthotics

3D printed orthotics are made based on a digital design and a 3D printer that follows that design exactly. No manual intermediate steps, no distortion, no differences in interpretation. You can be sure that pressure distribution and fit come out the way you intended. At Shapemakers, we print those custom-made orthotics for you. For podiatrists and orthopaedic shoe technicians who want a grip on quality and lead time. 

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3D scanning model for custom orthopaedics

What are 3D printed orthotics? 

3D printed orthotics are orthotics that are built up layer by layer by a 3D printer based on digital CAD design. The support zones, corrections and pressure distribution defined in the model are reflected by the system exactly as they are in the final product. Without any deviation. 

The basis of such a custom-made orthotic always comes from a supplied design. That design can come from: 

  • A 3D foot scan serving as the basis for digital design 
  • A corrected digital design in which support and fit are customised 
  • Previously saved digital soles to be reused or further refined 
  • Combinations of scanning information and manual corrections in CAD software 
  • Existing client data being developed for a follow-up sole 

At Shapemakers, we then turn that design into durable, lightweight custom-made orthotics using our 3D printers. 

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Traditional vs 3D printed orthotics 

Traditionally, orthotics are produced with foam box, plaster cast and manual construction. That process is sensitive to how you place the foot. To material behaviour. To the experience of the performer. Plus, in many cases, you have to make another foot impression when a patient comes back for a new sole. 

With 3D printed orthotics, we work from digital shoe technology. In doing so, the machines follow the digital design down to the millimetre. This reduces variables and ensures a predictable and reliable result. Every sole anew. Moreover, you can reuse the CAD files during re-production. 

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Materials: Foamy TPU and Programmable Foam 

At Shapemakers, we 3D-print custom-made orthotics in two materials, depending on the application and desired wearing sensation: 

  • Foamy TPU: Fomay TPU has the look and feel of EVA, the material widely used in traditional orthotics. Light, flexible and with a familiar wearing feel. Suitable for everyday use and a wide range of applications. 
  • Programmable Foam (Soft TPU): Programmable Foam is a softer material with more cushioning properties. Applicable where extra comfort, pressure distribution or protection is key, for vulnerable feet or specific orthopaedic indications. 

The choice of material depends on your design and the treatment objective. Shapemakers is happy to advise on the right choice.
 

Targeted support and pressure distribution established in design 

With an orthotic, it is important that the support is exactly where it should be. In a 3D-printed orthotic, this is all fixed. Correction zones, support zones per foot zone and pressure distribution are interpreted exactly as in the supplied model. What you design, the printer produces. 

As a result, you know in advance how the sole is going to function, and can work from the same digital base during follow-up treatment or adjustments. 

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3D printed commemorative statues

Benefits in podiatry practice and shoe technology workshop 

3D printed orthotics offer many advantages for podiatrists and shoe technicians: 

  • Faster turnaround time from measurement to delivery 
  • Constant quality in repeat productions 
  • Different material options to suit different applications 
  • Less post-processing required 
  • Digital storage of designs (no physical stock required) 
  • Higher patient satisfaction thanks to better fit and wearing comfort 
  • Better reproducibility in follow-up treatments and/or patient growth 
  • Scalable production without increasing workload 
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From digital design to custom-made orthotics 

At Shapemakers, we help you turn your designs into 3D printed orthotics, which is how production proceeds: 

  1. Delivery of design file via our portal 
  2. Technical control of printability and structure 
  3. 3D printing in the chosen material (Foamy TPU or Programmable Foam) 
  4. Quality control on form and finish 
  5. Delivery and immediate readiness 

Your design drives production. We make sure the final product matches it perfectly. 

 

Also have 3D printed orthotics made? 

Would you also like 3D printed orthotics? We would be happy to help you. Together, we ensure a smooth digital workflow in which you can have custom-made orthotics printed quickly and easily. Completely according to your software and working method. 

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What can we
help you with?

podiatry physiomed
Podiatry

Design and produce orthotics fully digitally. Work with fixed quality and a tight workflow from scan to 3D print.

Orthopaedic shoe technology
Shoe technology

Digitise lasts and fitting models with 3D printing technology. Reduce your lead time and work with consistent precision.

Production of orthoses and prosthetics
Orthoses and prosthetics

Optimise your production with 3D scanning and CAD/CAM. Reduce error margins and keep control over every step.

Mobility Sedora orthosis
Mobility

Produce custom-made products with 3D printing and milling. Speed up your delivery time and increase repeatability.

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What our customers have to say

Guido Shoes

(5)

"Since working with Shapemakers and scanning body parts instead of using plaster, our process has become on average a week faster. The... fit is noticeably better and more accurate, and in case of questions, Shapemakers is always readily available and willing to help. "

OIM Orthopaedics

(5)

"3D scanning allows us at OIM Orthopaedics to work faster, more efficiently and location-independently. With Shapemakers as a permanent partner in the... scanning and milling of orthopaedic instruments, we are taking a big step forward in quality and innovation. "

B&C Custom Bracing

(5)

"With B&C Custom Bracing's 3D printed knee brace, we are demonstrating how digital workflows make customisation scalable. Thanks to collaboration with... Shapemakers and Shapeshift 3D, we process a knee scan into a perfectly fitting design within minutes, without compromising on comfort, protection and freedom of movement. " "

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Talking opportunities

Would you like to know more about our options in podiatry? Then feel free to contact us.

Already a customer, and already have an account? Then you can access our customer-friendly order portal. Here you can order yourself and keep an eye on the order status.

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