Orthopaedic mould milling

We are specialists in milling orthopaedic moulds. For more than a decade, our production department has been milling moulds based on digital designs. From tubes and torso models to EVOs and seating orthoses. Our digital production gives your organisation instant certainty in accuracy and shape stability. The mould you design comes out exactly as it is. Completely finished, dimensionally stable and ready for the workbench. 

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What is orthopaedic mould milling? 

When milling orthopaedic moulds, a digital CAD file is converted into a physical mould via a CNC milling machine. The machine precisely follows the geometry of the file. Millimetre by millimetre. Whatever is in the file, the machine mills. 

Applications are wide-ranging. We mill tubes for prostheses, torso models, hand and arm orthoses, and complete seating and lying solutions in the mobility sector. All orthopaedic devices where size and accuracy directly determine whether the end product functions properly. 

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Milling orthopaedic moulds vs manual modelling 

Traditional moulds are built, ground and corrected manually. This requires experience and time. The result depends on who does it. As a result, every production is slightly different. And with a repeat order, you cannot therefore guarantee that it will be identical to the last time. 

With milled moulds, that variation disappears. The mould is a direct translation of the digital model. Your design is leading and the machine follows the model exactly. Each mould comes out exactly as you designed it. Regardless of who is behind the machine that day. 

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Full control over shape and size with milled moulds 

Any correction you incorporate into the CAD model is in the mould. Pressure distribution and correction zones are fixed in the file and the milling machine follows it exactly. What you design, you get back. That ensures predictable and reliable production. Every model again. 

And do you need certain a mould again? Then we simply turn it again. Identically or with a targeted modification if needed. Version management ensures that documentation always remains available and you don't have to start all over again. 

The advantages of milling orthopaedic moulds in the workshop 

Milling orthopaedic moulds in your workshop gives you many advantages:  

  • Fast delivery times through efficient production planning 
  • Constant quality in every production regardless of volume 
  • Less error-prone than manual modelling 
  • Exact reproduction for repeat orders 
  • Suitable for various orthopaedic moulds 
  • Moulds are ready for the workbench immediately (no post-processing required) 
  • Scalable production based on your needs 
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Material selection 

Material selection depends on the application and further processing of the mould: 

  • PIR: Rigid foam for rigid moulds and tubes. Good dimensional stability and machinable surface. Available in densities 80 to 300. 
  • MDF: Popular for pre-preg or leather models. Stable, with smooth surface and good machinability. 
  • Soft foam: Used in the mobility sector, such as reclining and seating solutions. 

We are happy to advise you on which material works best for your design and application. That way, you can be sure that your mould will soon do what you expect of it. 

 

From digital file to milled mould 

At Shapemakers, your design is leading every step of the way. Our milling machine follows every line, angle and curve to the millimetre. Without interpretation, without deviation. This is how the process works: 

  1. Delivery of design file via our portal 
  2. Technical control of milling 
  3. Conversion to milling programme 
  4. CNC mould milling 
  5. Quality control on sizing and finishing 
  6. Delivery: the mould is finished and immediately ready for use in your workshop 
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No need for in-house milling machine 

With Shapemakers, you don't need to buy your own milling machine. We work as an extension of your workshop. You benefit from the production capacity of our own milling department without having to worry about things like maintenance or specialist knowledge. You supply the design, we supply the mould.

Flexible. Scalable to your production needs. And directly integrated into your existing workflow. 

 

Also have orthopaedic moulds milled? 

Would you also like to have orthopaedic moulds milled? We would be happy to help you. You can start right away. We connect directly to your CAD software and design processes and provide you with all the support you need for your first orders. 

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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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info@orthoshapes.nl
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