CNC 3D Printer and its Use in the Orthotic Field

Sharp Shape provides new technologies in the field of foot orthotic manufacturing and production. Located in Silicon Valley, Sharp Shape always innovates. Recently, we made some significant advances in the orthotic industry including 3D printing software, besides the iPad Foot Scanner (AOMS TOT).

Latest Update:

While waiting for another breakthrough in 3D printer’s speed and materials, we have decided to release an orthotic design software. It is called AOMS 3DPRN. It is still in the beta testing phase. For information about it, please visit: www.sharpshape.com/aoms3dprn.html. We are releasing the software, hoping some companies out there have better solutions in terms of speed and material. Technologies are surely improving.

Previous results:

Recently we made some progress on the 3D-printer front. A business partner made this real-size orthotic (shown below) with his 3D printer. The material is ABS. The texture feels very nice. It is very clean and it looks like there are no supporting materials left. The only weakness remaining is the time. Although shortened, it still takes a little too long to make one. We are still making and waiting for a break-through. Click on one of the following two images to view the enlarged image.

Backside of 3D Printed Orthotic Backside of 3D Printed Orthotic


Some customers asked us about our readiness in 3D printing. We have followed the technology for more than 10 years and we have been developing software for custom 3D printed foot orthotics and insoles for many years. Right now, 3D printers made headlines and we took a closer look at the current technology. Further, we bought a 3D printer for R&D. Our concentration is on the 3D printer in the orthotic manufacturing field. Some findings are shown below and we want to share them with you.

Sharp Shape AOMS 3D Printer High Flange Orthotic Sharp Shape AOMS 3D Printer Lady

Note: I am able to hold the AOMS lady in my hand for the first time, owing to the 3D printer.

Pros

• Quick turn around for prototyping. No longer need a heavy CNC mill/router to make prototype models.
• Making parts that cannot be made with a CNC mill/router, for example, making a ball with a hollow inside.
• Small footprint. Suitable for small spaces.
• Less expensive now.
• More environmental friendly compared with CNC mill/router.

Cons

• Slower speed for production, compared with CNC mill/router. 4 to 5 hours for a single orthotic.
• Smaller build-area compared with the carving envelope of a CNC mill/router.
• Materials are very limited in options. PLA is most common. ABS is an option.
• Social concerns, like making firearm etc.

These pros and cons are changing with the improvements in technology. For example, the cost of the 3D printer is less expensive. $2,000 is a typical price. A CNC router costs $20,000. If we buy ten 3D printers and use them simultaneously, we may over come the slow-speed disadvantage.

For orthotic production, two major concerns have not been resolved. First is the production speed and second is the choice in materials.

Traditional CNC manufacturing process used on mill, lathe etc. is to remove (subtract) material from a material block, while the new CNC manufacturing process used on 3D printer is to build (add) material on a platform. From this point of view, the new manufacturing process is revolutionary.

Side notes: sometimes the 3D printing ended with errors (SD cannot be read or file error). A few times, the builds ended with mess-up. It is hard to decide to use ‘supports’ (the material underneath) or not. It is hard to clean these supports.

Our conclusions: it is a little too early to use the 3D printer in the orthotic productions now, because of the above mentioned facts. CNC mills and routers are still widely used in the orthotic labs now. This may change along with time.

Here are some videos and photos:

Click 'Play' sign to see video. Need speaker for sound.

Sharp Shape AOMS 3D Printer Foot Models Sharp Shape AOMS 3D Printer Orthotic Models Sharp Shape AOMS 3D Printer New AOMS Model Sharp Shape AOMS 3D Printer Rat Model