3D printed orthotics price

Aetrex Launches Program for $150 3-D-Printed Custom Orthotics – Footwear News

Aetrex, the market leader in comfort footwear, is launching a new 3-D-printed custom orthotic.

CREDIT: Aetrex

As part of its latest round of technological advancements, Aetrex is launching a 3-D-printed custom orthotic alongside its traditionally made insert and footwear lines. The product will be produced in partnership with EOS, the global market leader in industrial 3-D printing and additive manufacturing.

Aetrex has been renowned for comfort footwear since its inception in 1946 and for foot scanning since 2002, when it launched its first iStep scanner. This new technological innovation utilizes the company’s emphasis on comfort and newest Albert scanner to determine exactly what kind of support the customer needs in each area of the foot. For consumers, the custom orthotic should provide highly targeted comfort and alleviate pressure where they need it.

The 3-D-printed orthotic can be produced in under two weeks, from scan to receipt, but the process is highly technical. The Albert scanner comprises 5,000 gold-plated barometric sensors, 960 LEDS and receptors, and 18 cameras, which capture complete foot data with AI and computer vision-informed software. A pressure map of the foot is then created using 265 degrees of varying pressure for greater accuracy. The entire scan takes under 30 seconds.

“Our scanning technology is able to provide unmatched data about each unique foot which informs the resulting design — with complete data we can offer what is quite simply the most accurate custom orthotic available,” said Larry Schwartz, CEO at Aetrex Worldwide.

The new 3-D-printed orthotic will be individually designed to fit the needs of each foot.

CREDIT: Aetrex

Customers can expect to pay $150 for a custom orthotic. Upon purchase, the scan’s data is sent to the EOS printing facility. There, it is manipulated into a 3-D CAD drawing that takes into account the level of support that each individual foot will need in each area. The final design is then fed to the 3-D printer, and the finished item is shipped to the recipient.

For the consumer, the benefits are clear: a more accurate and personalized orthotic for improved comfort. However, retailers also stand to benefit, as the product requires no inventory and therefore no future markdowns for unsold product. Customer satisfaction is expected to be high due to the product’s individualized nature and the scanners themselves, of which 5,000 have been placed globally; they are also a popular tool to attract customers in-store due to the experiential factor.

Aetrex’s product launch comes as the footwear industry continues to home in on sustainable practices. The broader 3-D-printing model is in line with this mission, as it reduces waste through greater accuracy and to-order production; the Aetrex 3-D-printed orthotics also use recyclable materials that can be reincorporated into the production process. The program will be rolled out to select retailers in February 2019 and made available to a wider consumer base in the following months.

“Our drive to create a next-level custom orthotic started with the guiding principle that no two feet are alike,” said Schwartz. “Customers scan, we print, and we ship — it is that easy.”

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Why Choose 3D-Printed Orthotics? It’s All About Personalization

3D printing has come a long way since it was first commercialized over thirty years ago. It has become a go-to in many manufacturing circles, with a presence in industries such as medical, aerospace, and automotive, to name just a few. Manufacturers working under the strictest quality controls and hobbyists alike have grown to trust and rely on it because of its inherent benefits.

There are many reasons to love it — 3D printing can be cost-effective, help save time, be used to create complex structures, speed up time-to-market, and work for everything from one-off prototypes to series production.

When it comes to applications such as orthotics, some benefits stand out more than others. So, why should you choose this technology?

Make it personal

Every patient is unique. They’re built their own way, they move their own way, and they need orthotics that reflect that. This might be an issue for traditional manufacturing techniques, but not 3D printing. Because the design and printing process is entirely digital, foot and ankle experts can create a unique design, then print several pairs of orthotics simultaneously, all different from each other, making it a valid alternative for mass production.

For patients, this added level of customization lends itself to a perfect fit and happier feet with every step. That’s because every 3D printed phits orthotic begins with a CAD file, with a design based on patient data — dynamic measurements, to be precise. Instead of designing corrections based on a single scan of a patient’s foot, this technique relies on multiple, as well as gait and pressure measurements to create an average.

In doing so, foot and ankle experts can generate corrective insoles that are unique to each patient, based on their movement and the shape of their foot with greater accuracy than ever before — no more ‘one-size-fits-all’ that really fits no one — while ensuring that they remain comfortable, lightweight, and durable.

Thanks to nesting software, experts can print several unique pairs of phits simultaneously.

Accuracy and repeatability

As far as orthotics are concerned, this is a great improvement for foot and ankle experts. It allows them to build corrections into the printed base of the insole itself and apply different levels of stiffness where necessary. Unlike some traditional orthotics, this means corrective pieces are not glued on top of the insole itself, so phits are far less bulky and can be reproduced more easily.

Naturally, this improved design would be meaningless if the final product didn’t match it — but that’s no issue here. The 3D printing technique used to create phits orthotics is accurate down to 0.1mm. It would be impossible to reproduce a pair that was identical to the original by using manual techniques, and any minor differences could have a big impact on performance or patient comfort. With 3D printing, they can rest assured that the result will be the same every time.

3D-printed orthotics are accurate to 0.1mm, offering enhanced repeatability.

Made with expertise

While 3D printing offers a lot of freedom, getting the most from the technology isn’t easy. It requires a deep understanding of the process, from design to execution. Manufacturers must choose from a range of different materials and 3D printing technologies, such as selective laser sintering or fused deposition modeling (FDM), depending on the desired characteristics of their final product. If a product needs to be strong and heat-resistant or flexible and porous, there’s sure to be a combination that’s perfect for the job. Knowing where and when to use each combination comes from experience.

Thankfully, more than 30 years of additive manufacturing experience has been integrated into the Materialise Phits Suite workflow. Production is handled either by our experts at Materialise or approved partners depending on region, ensuring every pair of orthotics is 3D printed and finished to the highest possible standard.

Materialise Phits Suite and 3D printing

Having 3D printing as an integral part of the Materialise Phits Suite workflow really sets it apart for foot experts. They can expect benefits that other technologies cannot offer every time they design phits orthotics for their patients, beginning with the accuracy we mentioned earlier. The final result is guaranteed to match the design down to a margin of 0.1 mm, meaning it fits the foot exactly as intended right out of the box, with less back and forth for both parties. The same can be said for any replacements they print afterward.

For Fried Vancraen, Founder and CEO of Materialise, finding that Cinderalla fit was one of the main inspirations for venturing into the world of orthotics. He and his children endured the time-consuming process of measuring and changing insoles every year before Materialise Phits Suite was born. Now, they’re more than happy with orthotics that fit all occasions and styles and which, thanks to the durability of 3D printing, they know will stand the test of time.

Phits orthotics will fit into many different shoes, making every situation comfortable for your patients

When asked to describe the difference between traditional orthotics and her custom-made phits, it was this durability that really stood out for marathon world record holder Paula Radcliffe:

“Well, the biggest thing is the durability. They simply don't wear out! You can keep using them, you can run a lot of miles in them, and they basically don't show much damage at all. Only the top cover wears out, and these are easily replaced. The rest, it stays there the whole time. I think it's more precise than the traditional orthotics because it's exactly the same each time it's created, and it is lighter. It doesn't deform with heat and get as soft as with the traditional ones. Sometimes with the older ones, if it was very warm, they would build up, or they would get a hole or deform a little bit. phits orthotics don't do that!"

Making orthotics more sustainable

But there’s more to 3D printing than strength and style. Those seeking more sustainable options will also be impressed, particularly with powder-based technologies like SLS. In this case, the orthotics would be built layer by layer in a bed of powder, using only the necessary material, with waste reduced even further thanks to the use of 100% recycled powder. Whether your orthotics are printed by Materialise or by another local supplier, you’ll also benefit from simplified supply chains. Your design is made to order and shipped right to you, meaning there’s no middleman or storage necessary, further reducing the environmental impact.

Of course, none of this would matter if the process to actually create the orthotics was problematic, unreliable, or slow. In reality, 3D printing is nothing if not convenient. As an entirely digital manufacturing process, it can be integrated seamlessly into the digital orthotic ordering workflow — the gait is measured, the orthotic is designed in the footscan software before being sent to the printers. Foot and ankle experts can handle the entire process in Materialise Phits Suite and rest easy knowing that they’ll receive exactly what they ordered.

Say goodbye to paperwork

An added bonus of this end-to-end workflow is the clear reduction in paperwork. Because the necessary information and data is stored in the software, it has never been easier for foot and ankle experts to follow up on their patients in later appointments. Whether they need to create replacement orthotics or wish to see how an individual’s gait has changed over time, the information they need is never more than a click away.

Naturally, data security remains paramount. All patient data is securely stored in a separate, closed system, ensuring convenience doesn’t come at the expense of privacy.

Your end-users will love it, too

When patients receive their orthotics, many may not be too concerned with how they were made or where they came from. But that can change with Materialise Phits Suite. Experts can use the software’s visualizations, charts, and reports to explain the process from start to finish, including where any potential issues may stem from and how the construction of their 3D-printed orthotic can help resolve them.

With this software, experts can easily explain how and why phits will help their patients.

And there are plenty of other reasons to be happy about getting your hands on phits, starting with what matters most — comfort. Those who wear them, like British marathon champion Charlotte Purdue, quickly notice the difference that having orthotics shaped to fit their foot will have on how they move.

“When I first wore them, I found that they fit well, and I didn’t have any problems with them,” says Charlotte. “They fit my running style completely. If they didn’t, I’d have had blisters, or it wouldn’t feel right, but it felt like they needed to be in my shoes.”

Thankfully, an insistence on comfort doesn’t mean compromising on durability or performance. Because of their high-quality materials and engineered design, 3D-printed orthotics like phits are both lightweight and strong, meaning they’ll endure heavy usage for years and weigh about half as much as traditional, milled insoles. The soft, comfortable top cover is easily replaced when wear and tear kicks in, extending the life cycle even further, meaning phits aren’t just good for the environment but for the wallet, as well.

Athletes like Charlotte Purdue use phits every day, but they’re also great for day-to-day activities.

A big step forward for orthotics

Much like the analysis and design of orthotics has come far in recent years — it wasn’t long ago that foam boxes were the only available option — the introduction of 3D printing into the workflow is doing a lot to drive the industry forward to the benefit of everyone. It’s a big step forward for those who design orthotics and an even bigger step for those who wear them.

Materialise Phits Suite makes sure taking it has never been easier.

Process of making orthopedic insoles using the Raise3D printer

3D printing is a versatile form of additive manufacturing that is gaining popularity in a variety of fields. Currently, it is increasingly being used in plastic surgery and in the creation of orthopedic medical products and equipment. 3D printing has come to be used to improve medical devices due to the production stability and time efficiency it provides. An example of such an application can be seen in the collaboration between the Italian company CREA3D and the orthopedist Dr. Valenti. They are successfully combining 3D printing with other digital technologies to produce customized insoles and other custom-designed orthotics, thus enhancing the effectiveness of assistive care.

Dr. Mirko Valenti used 3D printing technology to treat clinical cases of tibialis posterior tenosynovitis with conservative corrective therapy. The introduction of technology into the treatment process was both innovative and highly effective. Valenti purchased a Raise3D E2 3D printer equipped with IDEX technology (independent dual extruder) for his office. The Raise3D E2 is ideal for printing a pair of orthopedic insoles at the same time.

Individual orthopedic insoles

Traditional manufacturing of insoles before 3D printing

Each pair of orthopedic insoles is individual for a particular patient, because everyone has their own needs. The strength properties of the various parts of the insoles must be adjusted according to individual characteristics.

This proved to be a problem for the traditional manufacturing process. The traditional process requires using a CNC machine to mill a piece of material into the desired shape. To ensure the accuracy of the anatomical region in the insole, a high-precision CNC machine and high labor costs are required. This is a laborious and complex process. The production process creates a lot of garbage and dust, pollutes the working environment, endangers the health of workers.

Manufacture of insoles after the advent of 3D printing

Abandoning traditional CAD-CAM machines, Dr. Mirko Valenti began to print orthopedic insoles with PP plastic thread. Due to the durability and strength of the material, excellent support for the patient's foot is provided. Printing a pair of orthopedic insoles with PP thread is a simple process.

First, the doctor scans the patient's leg. He then uses a CAD program to make a model of an orthopedic insole with compensating supports for the affected areas, thereby ensuring that the arch of the foot is supported and the heel is stable. Valenti then loads the model file into ideaMaker 3D print preparation software to optimize technical properties such as shape change and infill percentage of the model. For example, honeycomb infill can make the structure rigid. The filling allows different results in terms of deformability and softness of the orthosis. Then the doctor uploads the model file to the E2 3D printer, which prints out a pair of insoles at the same time. Finally, Dr. Valenti wraps the sole with EVA or other special materials suitable for skin contact.

The entire manufacturing process, including scanning, design and production, takes less than 24 hours.

Benefits of 3D oven orthopedic insoles;

3D printing simplifies the traditional process and shortens the production cycle, as well as the time it takes for the customer to receive the product. A 3D printed model can be produced in a single process without the use of any other additional machines and tools. Printing a pair of orthopedic insoles on the Raise3D E2 printer takes only 2-3 hours, and the whole process is done automatically without the need for manual control. Making insoles without 3D printing requires a lot of hand tools, a lot of time to get an accurate model according to the anatomical features. 3D printing makes it possible to successfully carry out individual orthopedic treatment.

3D printing is an efficient manufacturing process

3D printing is a more efficient process for producing insoles. Users can design models and mass-produce them at the same time. With 3D printing, there is no need for multiple design, verification, and modification processes. 3D printing makes it possible to produce small batches on demand. The model is available immediately.

Enclosed 3D printers provide a greener working environment

Enclosed 3D printers like the Raise3D filter out any fumes that are released when the material is heated during 3D printing. This reduces the need for large workshops or separate production rooms. As a result, 3D printing provides a cleaner and healthier environment. You can perform mass production right in the office.

Correct software for 3D printing

Dr. Valenti chose polypropylene as the material for the 3D printing to provide support and flexibility for various insoles. Each kind of polymer needs different settings. The right software can greatly simplify the job of customizing settings.

For example, ideaMaker is a file-to-print software that has many built-in preset templates for various polymers (including polypropylene).

The main advantage is that users can adjust internal structure parameters such as infill density, infill angle, and others to control strength properties.

Adjust the model properties in ideaMaker to prepare the model for printing.

Raise3D provides a complete process for the production of orthopedic insoles

Dr. Valenti chose the Raise3D E2 desktop 3D printer for the production of orthopedic insoles. As a medium-sized professional desktop printer, the E2 meets all print quality requirements. At the same time, E2 is suitable for home and small studios. IDEX E2 technology allows users to print a pair of orthopedic insoles at once, maximizing production efficiency. In addition, during the manufacturing process, Dr. Valenti uses ideaMaker 3D printing file preparation software to reinforce the internal structure of the insole. ideaMaker has parameter settings and various templates, allows you to customize and change the technical properties of the insole. The E2 desktop 3D printer supports a variety of plastics, including polypropylene. Users can learn about polymer characteristics and download related files.

3D printing will benefit more medical fields

3D printing provides better customization, precision, aesthetic appearance and lightweight structure. It also significantly reduces the manufacturing process and lead times and fabrication. Dr. Mirko Valenti used 3D printing in the manufacture of plantar orthoses. He used Raise3D printers and software for a full production cycle and achieved high efficiency thanks to the Raise3D ecosystem.

The material is provided by the Italian distributor of Raise3D - Crea3D.

How to 3D print economical and customized insoles?

Orthopedic insoles appeared after the Second World War as a means of treating biomechanical diseases of the lower extremities. Orthotic insoles have become a popular treatment option due to their easy availability and wide range of uses. For example, about 9.4% of the American population, or 30.3 million Americans, currently have diabetes. More than 70% of Americans suffer from overpronation. Many who suffer from these diseases need orthopedic insoles.

For over 70 years, the manufacturing process of orthopedic insoles has relied heavily on manual labor and CNC machining. This heavy reliance on both methods led to high costs and significant production times, as well as a constant risk of deviation in production accuracy. With the advent of 3D printing, the manufacturing process has changed a lot.

Raise3D Collaboration with Teaching Hospital and “3D Printing Clinic”

Raise3D is working with an innovative clinical hospital to bring FFF 3D printing to the production of orthopedic insoles. The hospital already had an idea of the decade-long success of 3D printing and had high demands on any insoles made using this method. As a result, it was decided to introduce 3D printing in combination with other digital technologies in the manufacturing process.

A “3D printing clinic” has been set up at the hospital, which operates with additional technical support from the university's biomechanical laboratory. This technical support allows you to use the latest analysis, scanning and design technologies.

Insoles printed on the Raise3D E2 desktop 3D printer with ideaMaker 3D cutting software retain their high performance. Moreover, the method is cost-effective.

The hospital was satisfied with the efficiency of the process and high productivity. It was decided to use Raise3D products and the company's technical support. The Raise3D orthopedic insoles solution includes a 3D printer, model cutting software, cutting template and plastic.

The hospital focuses on diagnosing and designing insoles, as well as improving the 3D printing process in-house. During this time, Raise3D provides technical support and advice. Raise3D helps optimize print settings and teaches you how to operate the equipment. The user-friendly interface of Raise3D hardware and software ensures that medical staff can easily operate and schedule the 3D printer, thus saving time and labor.

Through a combination of 3D printing and a digital manufacturing process, the clinic hosts a complete insole manufacturing process in-house. Every month, patients from all over the country come to the clinic, and their number continues to grow.

Manufacture of orthopedic insoles before 3D printing

The traditional process for custom-made orthopedic insoles is complex because each pair of insoles is unique. The insoles must have different mechanical properties in different parts of the sole to help correct a person's posture. For example, a person with uneven arches and overpronation will need different arch support for each foot. The traditional method usually involves forming and stacking different sheets of material on top of each other. Each leaf is shaped, assembled and polished. Even when using CNC machines, this process requires a lot of manual labor.

3D printed insoles

Because all it takes to 3D print is a workbench, computer software, and a 3D printer, the clinic can do the entire process in-house. The only thing medical staff need to know is a few relevant settings that can be configured with a few clicks.

Raise3D's E2 desktop 3D printer prints one pair of insoles completely in about 2 hours with no additional labor required. With additional support for RaiseCloud, Raise3D's cloud-based 3D printing management software, hospital operators can remotely monitor print progress in real time. Because RaiseCloud is a cloud-based platform, it can always be accessed over the Internet, greatly increasing the efficiency and flexibility of print management.

Productivity and cost of producing insoles on a 3D printer

3D printed insoles have better performance than conventionally made insoles. For example, 3D printed custom insoles have an open structure, making the insole lightweight and breathable. Another benefit is that 3D printed insoles have a more precise and flexible stiffness distribution on the inside. This is very important for effective treatment. Raise3D 3D printed insoles use TPU material, which has better mechanical properties, namely durability and strength, especially when compared to traditionally made insoles. The patient will feel constant support throughout the entire time the 3D printed insole is worn.

High performance 3D printed insoles are also cost effective to manufacture, especially when compared to the cost of producing conventional insoles. This is because the cost structure of 3D printing is different from traditional manufacturing. For example, by adopting 3D printing, a hospital can reduce the need for various types of equipment and tools. This saves on asset costs and workspace costs. It also reduces labor and material costs.