Why are 3D Printed Orthotics so Amazing?

Why are 3D printed orthotics a step up from standard ones? This article looks at the differences between regular and 3D printed orthotics so you can make an informed decision for yourself.
Premier Orthotics Lab uses cutting-edge 3D technology to improve symptoms and guarantee comfort. 3D printing technology helps medical specialists be as involved in orthotics design as possible. Podorthists design and develop the orthotics, which is the best option – having them created by experts.

3D Orthotic Insoles

A highly precise printing process

Providers of this product and service start by scanning the patient’s feet with a laser to create a digitized 3D image. Then, the orthotic is designed in-house by the podiatry team using special design software.

Experts combine their expertise and knowledge, information from an evaluation of the patient’s postural issues or pain, information about foot and leg position, and data from the unique shape of the foot.

The people designing your orthotics have in-depth understanding and knowledge of feet and foot issues in this process, where they are designed in-clinic and not merely prescribed by a podiatrist and designed off-site by a lab technician. This understanding and knowledge are transposed onto the design parameters.

Benefits of 3D printing technology

This technology creates an elegant, light, and slim orthotic that ensures top-notch support but can adapt and flex with the foot at the same time. The process is completed with any necessary additions to ensure maximum comfort and relief of symptoms.

Regular orthotics are made using a large block of foam or plastic, creating a bulky, less accurate, and relatively heavy product. Another disadvantage of this process compared to 3D printing is the rather large amount of waste created. 3D printing creates far less waste.

Premier Orthotics Lab has found a reduction in the number of follow-up exams needed due to improved symptom relief and comfort. The technology has also made it easy to duplicate orthotics – a second or third pair is just a click away. You can insert them in as many pairs of shoes as you wish.

As a result of all of this, more and more people are turning to 3D printing. This technology is becoming more advanced by the minute. It is present not only in the medical industry but also in the automotive and aerospace ones. Its innate benefits have led consumers worldwide to rely on and trust it. For their part, manufacturers are working under strict controls to ensure top quality.

3D Printing Orthotics


3D printing can be personalized and cost-effective and can help save time. It can work for series production, one-off products, and everything in between. It accelerates the time to market and can be applied to create highly specific and complex structures.

Every person has unique feet. They need a personalized and customized orthotic to reflect this uniqueness, which is where 3D printing truly excels. Ankle and foot experts can easily develop unique designs because the printing process is fully digital. They can print multiple pairs of orthotics at the same time, and they will all be unique. In this way, 3D printing becomes a viable alternative for mass production.

Patients benefit from this enhanced customization, enjoying the comfort and a better fit with every step they take. Each orthotic starts its journey as a CAD file. The design is based on dynamic measurements. The technique relies on numerous pressure and gait measurements to come up with an average rather than making a single scan of the foot and then designing corrections.

In this process, ankle and foot experts can create unique insoles for each person based on the shape and movement of their feet. The one-size-fits-all approach has become a thing of the past. Such insoles actually fit no one. 3D printed insoles are durable, light, and comfortable and retain these properties over time. You will always get relief from them. If corrections are needed, they are easy to make.

Replicability and precision

The experts printing orthotics in 3D can build adjustments into the insole’s printed base. If needed, they can apply varying levels of stiffness. Corrective elements aren’t glued to the orthotic, making it bulkier and less comfortable, unlike traditional orthotics. This also makes them easier to reproduce.

3D printing is accurate down to a fraction of a millimeter. One couldn’t apply a manual technique to reproduce a pair identical to the original one. Even the slightest difference impacts comfort and performance. 3D printing ensures effective replicability.

Range of technologies and materials

Producers select from a range of technologies and materials, such as fused deposition modeling (FDM) or selective laser sintering (SLS), depending on the end product’s desired properties. You can choose exactly how the final product will be: porous and flexible, heat-resistant, etc. It’s always possible to get the right combination if the manufacturer has sufficient experience. Thankfully, that’s the case with Vida, whose experts have decades of collective manufacturing experience. Every pair of insoles is printed and completed to the highest possible standard.

A guarantee for sustainability

There’s more to this technology than style and performance. SLS and other powder-based technologies are used to build insoles in a bed of powder, layer by layer, using only the material necessary. The use of fully recycled powder reduces waste even further. The end user also avails of simplified supply chains. Premier Orthotics Lab ships the design right to you, the end user, meaning no storage or intermediaries are necessary, which ultimately minimizes the environmental impact.

The ultimate in convenience

3D printing is reliable, fast, and entirely unproblematic. The manufacturer measures the gait, designs the insoles using foot scan software, and prints them. The process is integrated into the ordering workflow seamlessly. You’ll get exactly what you ordered.

The software stores all the necessary data and information, leading to a marked reduction in paperwork. Follow-up appointments have never been easier to make, not to mention the need for these is reduced. The information experts require is a click away, no matter whether they want to see if the patient’s gait has changed or need to create replacement orthotics.

Secure personal data storage

A closed, separate system stores all patient data safely and securely, ensuring that no compromise on privacy is made in the name of comfort and convenience. The software’s reports, charts, and visualizations are used to explain the whole process, including the causes of potential issues and how 3D-printed orthotics can help avoid them.

Final thoughts on 3D Orthotics

Premier Orthotics Lab generates and delivers customized orthotics for your clinic through our 3D printing technology. We have manufactured orthotic insoles for over two decades. Contact us to discuss how Premier Orthotics Lab can help your clinic today!

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