Orthopaedic 3D moulds

Almost every orthopaedic device starts with a mould. The mould is the base on which the orthosis or prosthesis is built. If that base is wrong, the final product is wrong too. Shapemakers mills orthopaedic 3D moulds based on your digital design. Dimensionally stable, exactly reproducible and immediately ready for use. 

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What are orthopaedic 3D moulds? 

Orthopaedic 3D moulds are basic moulds used in the production of orthoses and prostheses. They represent the shape of the body part and the intended corrections. In doing so, they form the basis on which the device is constructed, shaped or laminated. 

The quality of the mould determines the quality of the final product. A mould for a socket or prosthetic stump that is not exact will result in an orthosis or prosthesis that does not fit exactly. This is not a theoretical risk, but a daily reality in workshops working manually. 

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Digital vs manual modelling 

Manual moulds are built with a plaster model, corrected with a rasp and orbital sander and updated until the shape is good enough. That process is labour-intensive and highly dependent on the experience of the specialist. Making exactly the same mould therefore often proves difficult. 

With digital manufacturing, you ensure more consistency in quality. The CNC router follows the CAD model with extremely high accuracy. So the same job always gives the same result, regardless of who supplied the file or how much time there is between productions. 

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Full control over shape and size 

Any correction you incorporate into the model is in the mould. The geometry you draw, you get back exactly the same. And because every version is stored digitally, you can always see which mould was produced when. Useful for long-term treatments, when the patient grows or when transferring to a colleague. 

Advantages of digital manufacturing 

Producing your orthopaedic 3D moulds digitally ensures customisation with less post-processing in the workshop, shorter lead times, less error proneness and reproducibility with consistent quality. But perhaps more importantly, digital production is predictable. You and your patients know in advance exactly what to expect. That ensures peace of mind and avoids surprises afterwards. 

 

Orthopaedic 3D moulds from your digital design 

At Shapemakers, your milling department is remote. For you, that means no milling machines, no specialist CNC knowledge and no maintenance. You scan the body part with a 3D scan, make the corrections in your CAD/CAM software and submit the file. We mill without adjustments or interpretations. What you get back is exactly the orthopaedic 3D mould you supplied. 

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Material selection 

Shapemakers mills from two material types, depending on the application: 

  • PIR (rigid foam): Suitable for rigid moulds in prostheses and orthoses. Good dimensional stability, machinable surface and available in densities 80 to 300. 
  • MDF: Stable material with a smooth surface that is easy to work with. 

Which material is best depends on the final product and further processing. At Shapemakers, we are happy to think along with you on this. 

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From digital file to orthopaedic 3D mould 

When outsourcing production, Shapemakers always fits easily into the existing digital workflow. So we go from digital design to orthopaedic 3D mould that can be used directly in the workshop:

  1. Delivery of the digital design file 
  2. Technical control of millability and structure 
  3. Conversion to milling programme 
  4. CNC mould milling 
  5. Quality control on sizing and finishing 
  6. Delivery: ready for further processing in your workshop 

Get your orthopaedic moulds produced by Shapemakers 

Also milling orthopaedic moulds without your own milling machine? Submit your CAD file via our portal and we will ensure reliable production with fast delivery times. For 3D moulds that always precisely match your design. Every time. 

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What can we
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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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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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