Innovation

3D printing is transforming custom orthotics

Mar 16, 2025

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3D printing is changing how orthotics are designed and produced - making it easier to create highly personalised support with consistent quality. Instead of relying on manual processes, digital workflows allow orthotics to be designed using scan data and biomechanics, then printed with precision.

Research highlights that 3D printing can improve repeatability, accuracy, and turnaround time. For patients, this often means a better-fitting device and a more predictable experience. For clinicians, it supports more control over fine design details - like thickness, reinforcement zones, and functional support - based on clinical goals.

It also supports more efficient manufacturing, reducing material waste and enabling strong, lightweight designs that maintain comfort without compromising support.

Key insights (summary)

3D printing improves precision, repeatability, and consistency in custom orthotics.
Digital design enables fine control over support zones tailored to patient needs.
Advanced manufacturing can reduce waste and support lighter, durable solutions.