Digital orthotic workflow
CAD design
CAD design services for custom orthoses, from 3D scan to manufacturing-ready file.
Custom orthotic CAD design
Turning your scan or idea into a finished design
We provide CAD design services for custom orthoses, helping clinicians and manufacturers turn 3D scans and clinical requirements into practical, manufacturing-ready designs. From AFOs and insoles to spinal orthoses, helmets and bespoke splints, we can support the design process from the initial scan or concept through to the final CAD file.
Send us a 3D scan, existing design, sketch or clinical specification, and we can develop it into a digital orthotic design. We use specialist orthotic CAD software to shape and refine the design around the patient’s anatomy and the requirements of the device, adjusting alignment, thickness, relief areas, openings, ventilation, fastening systems and other features needed for the final product.
The design can then be prepared for 3D printing, CNC milling, vacuum forming or other manufacturing methods, depending on how the device will be produced. If you already have a design, we can also help modify or develop it further.
Our process
How it works
Send the scan
Send the patient’s 3D scan along with any prescription details, measurements, clinical notes or design requirements. STL and OBJ are commonly used file formats, but other formats can be discussed depending on the project.
CAD design
We create the orthotic design using specialist CAD software, taking into account the scan, clinical requirements and intended manufacturing method.
Review the design
Before the design is finalised, we can provide images or 3D views for you to review, so you can check the design and request any changes before it goes into production.
Ready for manufacturing
Once everything is agreed, we provide the final CAD or STL file ready for your chosen manufacturing process.
Turnaround time: typical design turnaround is 3–5 working days, depending on the complexity of the case.
Bespoke solutions
What we can design
AFOs & Lower-Limb Orthoses
Custom AFO designs, including solid, articulated and other lower-limb orthoses.
Insoles & Foot Orthoses
Custom insole and foot orthosis design from 3D foot scans, prepared for 3D printing, CNC milling or other manufacturing methods.
Spinal Orthoses
Digital design of custom spinal orthoses and spinal jackets, developed around the patient’s shape and the requirements of the device.
Protective & Cranial Helmets
Custom orthotic helmet design from 3D head scans, including ventilation, padding, fastening and other design features.
Splints & Upper-Limb Orthoses
CAD design for custom hand, wrist and upper-limb splints and orthoses.
Bespoke Orthotic Designs
Have an idea that doesn’t fit a standard product? We can help develop bespoke orthotic designs and prototypes, from initial concept through to a manufacturing-ready model.
From 3D scan to manufacturing
Have a design you need help with?
Whether you have a 3D scan, a rough sketch, an existing CAD model or simply an idea, get in touch and let’s discuss the project. We can help turn it into a practical custom orthotic CAD design ready for manufacturing.