3D-printed custom orthotics with multi-density zones
Clinical-grade 3D-printed orthotics with variable stiffness across arch, heel, and forefoot. Ready for fitting, no post-processing required.
What sets them apart
- Variable density zones controlled digitally.
- Medical-grade thermoplastic material, heat-adjustable.
- Same-day reprinting of revised versions.
- No lab turnaround, no physical impression to ship.
Typical clinical cases
- Progressive flat foot: incremental arch rigidity adjustments.
- Metatarsalgia: targeted offloading, tunable to patient response.
- Plantar fasciitis: heel posting adapted over the course of treatment.
How they are built
Multiple densities, precise correction by zone
Design with different hardnesses to offload specific zones under the foot. You improve the effectiveness of the device with correction and comfort levels set independently for each section: arch, heel and forefoot.
Grind it, modify it, or reprint in hours
Podform3D orthotics grind and sand exactly like conventional EVA using your existing bench grinder or rotary tool. Relieve a bony prominence, bevel the edges, reduce heel cup height: no new equipment and no retraining, because your technicians already know the moves. You can also modify the digital design and reprint in hours.
Clinical grade, lightweight, durable
A purpose-built filament that stands up to daily wear. Breathable structure for patient comfort. Compatible with all standard top covers.
Finishing, the way you already work
No new equipment required. Use pre-glued pad and top cover materials to finish devices in seconds: lightly heat the orthotic surface with a standard heat gun and the pre-activated adhesive bonds on contact. No spray glue, no drying time, no mess. Compatible with all standard pre-glued materials.
Printed compared with milled
This is the natural evolution for clinicians who use milled orthotics: 3D printing delivers a far superior degree of precision in stiffness configuration without changing how you approach your treatment plans. All parameters are set directly in the application, intuitively, and respecting the clinical gestures inherent to each approach in foot care. The material lets every practitioner implement their own style and clinical decisions, down to a tenth of a millimetre, on models matching every class of practice and pathology.
Treat the orthotic like a prescription
A prescription is not final on the first try. You evaluate, adjust the dose, and refine until the outcome is right. Orthotics should work the same way.
With in-clinic production you are no longer locked into a one-shot design by a 3-to-4-week turnaround. Patient needs more medial arch support? Increase rigidity in zone 3 and reprint in two hours. Forefoot offloading not aggressive enough? Adjust density and reprint the same afternoon. The digital file is always on hand, ready for the next iteration.
This changes the clinical conversation. Instead of "let us wait and see if the new pair works", you tell your patient: "come back tomorrow and I will have the adjusted pair ready". Compliance goes up and outcomes improve.
Works with your existing finishing tools.
Podform3D orthotics grind and sand exactly like conventional EVA using your existing bench grinder or rotary tool. Relieve a bony prominence, bevel the edges, reduce heel cup height. No new equipment. No retraining. Your technicians already know the moves.
Use pre-glued pad and top cover materials to finish devices in seconds. Lightly heat the orthotic surface with a standard heat gun. The pre-activated adhesive bonds on contact. No spray glue, no drying time, no mess.
EVA padding, microfiber top covers, Poron inserts, leather covers. If it's pre-glued and heat-activated, it bonds directly to the orthotic.
The real advantage: milled orthotics cannot vary stiffness by zone. 3D printing can.
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Contact Dr. Antonin Berube at antonin@podform3d.com.