Milling for mobility

What mobility solutions can we mill?

We mill components for seating and reclining solutions, including both complete moulds and individual parts that you can then process or assemble yourself. These include seat shells, complete seats, back supports, reclining moulds, positioning blocks, wedge moulds and other structural components for seating and reclining systems.

Do you have an unusual shape, an atypical size or a one-off bespoke product? Please get in touch with us. Even if it’s not on the standard list, we’d be happy to assess whether it’s feasible.

From scan to milled seating or recumbent solution

The process can be summarised in eight steps:

You record the individual’s sitting or lying position, for example using a vacuum bag and a 3D scanner.
You import the scan into your design software.
You will model the seating or recumbent solution, incorporating the required support, pressure distribution and positioning.
You provide us with the digital design file.
We carry out a technical check on the file to ensure it is suitable for production.
We prepare the file for the CNC milling machine.
The component is milled and checked for dimensions and finish.
The product is delivered to you, ready for further processing, finishing or assembly.

You determine the fit, the support strategy and the corrections. We assess the file from a technical perspective, not from a medical or treatment-related point of view. The design you provide is and remains the basis for the milled product. We will not modify your design without consulting you first.

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Milling or 3D printing?

Within the mobility sector, we utilise both CNC milling and 3D printing. Milling is particularly suitable for larger, flatter shapes and structural components. We opt for 3D printing for more complex geometries or when a component requires specific material properties, such as multiple pressure zones within a single product.

Take our Programmable Foam®, for example. This is a 3D-printed seat with a gyroid structure that combines soft and firm zones within a single cushion. The seat is washable at 60 °C.

We can combine both techniques within a single seating or reclining solution, for example a milled shell with a 3D-printed cushion insert. Which method is most suitable depends not only on the shape, but also on the material, the desired support and the subsequent processing. We are happy to advise on this for each individual design.

Materials for milled mobility solutions

For milled mobility solutions, we work with a variety of materials. The choice depends on whether the component needs to provide comfort or structural support.

We use soft foam for cushions, backrests, seats and mattresses. These are components where comfort and pressure distribution are paramount. We mill this in grades such as HDH 35100 and Polyether 4080.

We opt for PIR rigid foam for stiffer, structural components, such as positioning blocks and support structures. This material is available in densities ranging from HSI80 to HSI300. A lower density is suitable for lighter work involving less stress. We use a higher density where greater strength or precision is required.

We use MDF where a component needs to be particularly strong and dimensionally stable.

Which material and density are most suitable depends on the design and function of the component. Does it need to provide comfort, relieve pressure points, or, conversely, offer structure and rigidity? We advise you based on your specific application. A different material or density can always be discussed in consultation.

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Why outsource milling work for mobility solutions?

Owning your own CNC milling machine requires an investment, a milling programmer and specialist knowledge of the machine. Do you outsource your milling work? Then you don’t need to invest in this yourself and you’ll have extra production capacity available as soon as the number of orders increases.

Other practical benefits:

Less manual cutting, grinding and correction work.
More consistent sizing for new and repeat orders.
Digital designs are stored and can be easily reproduced.
We tailor previous designs specifically to the user’s changing circumstances.
Reduced reliance on a single person to manufacture the product by hand.
This leaves you with more time for design, fitting and supporting the user.

Would you like to know what this means for your lead times, order quantities or an urgent order? Please get in touch. We’ll then work with you to see what’s feasible.

Part of a digital mobility workflow

From vacuum bagging or body measurements to scanning, digital design and production: the milling process integrates seamlessly with your digital workflow. You submit your design file via our order portal. We mill the component. You can always have previous designs reproduced or specifically modified.

We process changes, new versions and repeat orders digitally, so you never lose a design.

Are you new to this approach? We’ll work with you to implement the digital workflow and support you with your first orders. Want to know more about scanning or design software for mobility? Take a look at our relevant pages.

Technical support for the milling process

Where we do contribute ideas:

Check whether your file is technically suitable for production.
Advice on milling or 3D printing.
Advice on materials, hardness or density.
Answering questions about file types and submission.
Integrate with your existing scanning and design software.
Supporting you with your first assignments.
We can help you find solutions for unusual shapes or non-standard applications.

What we do not provide:

The treatment strategy.
The medical assessment of sitting or lying posture.
Identifying pressure points or pressure-relief zones.
Adjusting the fit without your instructions.
The functional requirements of the aid.

If a file is technically unsuitable for production, we will always contact you first before proceeding.

Need a mobility solution milled?

We mill components for seating and recumbent solutions based on your digital design. From seat shells to positioning blocks, precision-machined and ready for further processing.

Are you a new customer? Please contact us to arrange an introductory meeting or a technical consultation. Are you already working with us? Submit your design directly via the order portal. Are you unsure about a specialised product or an alternative material? Please discuss it with us first.

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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. " "

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.

0318 253 046

info@orthoshapes.nl