Outsource orthopaedic manufacturing

At Shapemakers, we operate as an extension of your workshop: you determine the design and the technical adjustments, and we convert the digital file into a milled mould or a 3D-printed product. 

Sound familiar? Limited capacity, high investment costs for your own machine, fluctuating workload or simply no in-house specialist for production. Whether it’s a one-off order or regular production, we’re happy to help. Discuss your production needs with us and we’ll explore the options. 

Discuss the possibilities
3D scanning model for custom orthopaedics

Which orthopaedic production processes can you outsource? 

Shapemakers manufactures a wide range of orthopaedic products, both milled and 3D-printed. 

For milling, we can, amongst other things: 

  • orthopaedic moulds 
  • Prosthetic models 
  • Torso models/Corsets 
  • models for arm and leg orthoses 
  • seating and recumbent moulds 
  • other positive models 

For 3D printing, we can, amongst other things: 

  • orthoses 
  • components for prostheses 
  • prosthesis sockets 
  • Corsets 
  • orthotics 
  • other direct end products 

Which technique is most suitable depends on your design, the desired material and the subsequent finishing process. Do you have a production challenge that doesn’t fit into this list? Let us know, and we’ll work with you to explore the technical possibilities. 

Milling table Image

Outsourcing milling 

We use CNC milling to produce dimensionally accurate orthopaedic moulds and models, ranging from sleeves to complete corset shells. The milling machine follows your digital CAD file directly: all the corrections and dimensions you have specified are literally reproduced in the mould. 

We mill PIR foam in various densities (HSI80 to HSI300) and MDF, depending on the application and desired rigidity. The mould is delivered clean and inspected; any further finishing, such as lamination, is carried out by you in your workshop. Do you need a previous model again? We can mill an identical copy based on the same file. 

Don’t have your own milling machine or lack sufficient in-house capacity? Then outsourcing is a logical step. We’d be happy to discuss the options, lead times and any rush options when you make your enquiry. 

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Outsourcing 3D printing 

As well as milling, we also 3D-print finished products and components directly: orthoses, prosthetic sockets and components, corsets and orthotic insoles.  

We work with multiple printing techniques and materials (MJF, SLS and FDM, including TPU, PA11 and PA12), depending on the application and the required properties. Some products are ready for immediate use, whilst others serve as components for further processing in your workshop. 

If you submit your file in accordance with our technical specifications, we will check the dimensions and wall thickness before we begin. After printing, we carry out the post-processing required for the product, such as vapour smoothing or the removal of support structures. Do you have a non-standard design, a prototype or a new application? Let us know, and we’ll work with you to see what’s feasible. 

Why outsource orthopaedic production? 

No need to invest in your own milling machine or industrial 3D printing system. No costs for maintenance, breakdowns, materials or machine management. No need to hire or train a dedicated production specialist. 

What’s more, you gain extra capacity during peak periods, are less reliant on individual staff members and can maintain a more consistent production rate, as everything is based on a digital file. Need a previously made product again? We can produce it in no time. And with production taken off your hands, your practice has more time for measuring, designing, fitting and treating – in other words, the patient or client.  

Outsourcing isn’t just for high-volume production. It’s just as beneficial if you produce on an occasional basis, want to gain experience with digital manufacturing first, or need to temporarily supplement your own capacity. You can utilise new techniques without having to purchase equipment yourself straight away. 

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3D printed commemorative statues

This is how production works at Shapemakers 

  1. You will be responsible for the digital design. 
  2. You submit the file via our order portal. 
  3. We carry out a technical inspection. 
  4. We determine the most suitable production method. 
  5. The product is milled or 3D-printed. 
  6. We check dimensions and finish. 
  7. The product will be delivered to your door.

During the technical review, we examine aspects such as manufacturability, wall thickness and dimensions. If any issues arise, we will contact you promptly to ensure production does not suffer any unnecessary delays. Production begins as soon as the file has been approved.  

You can track the exact status of your order via the order portal. We process modifications and repeat orders based on the file you previously supplied. 

Shapemakers’ services 

We don’t just supply a product; we work with you to optimise your entire digital production workflow. Are you unsure about a file type, the manufacturability of a design, the right material or the choice between milling and 3D printing? We’d be happy to help you with that. 

We support new clients with their first orders to ensure a smooth transition to outsourcing. If you have any questions, we’re always easy to reach. Via the order portal, you can see the status of all your orders at a glance. If a file you’ve supplied cannot be produced straight away, we’ll get in touch to work out a viable solution together. 

What makes Shapemakers a suitable manufacturing partner? 

Over fourteen years’ experience in the digitalisation of orthopaedic production processes. We are not only familiar with the software and machinery, but also with the production process itself. Milling and 3D printing from a single partner, with experience across a wide range of orthopaedic products. 

We carry out a technical check on every file before it goes into production. You can place and track your orders yourself via the order portal. And if your production needs grow? We’ll grow with you, providing support as you digitise your entire workflow. 

Are you considering outsourcing orthopaedic production to Shapemakers? 

From milled moulds to 3D-printed orthoses and prosthetic sockets: Shapemakers takes care of production for you, whether on an occasional or regular basis. Do you have an unusual or new production challenge? We’d be happy to discuss that too. A digital design file is usually sufficient for an initial assessment. If you’re already a customer, place your order directly via the order portal. 

Discuss your production requirements
Daniel van Krevel

What can we
help you with?

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

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

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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.

0318 253 046
info@orthoshapes.nl
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