AOMS TOT CNC
- Milling 'As-Is' Foot Orthotics From AOMS TOT Scans
We believe AOMS TOT CNC is a jewel based on our many years of experience in the foot orthotic automation field. We are so confident with our belief that we allow you 'pay-per-use'. If you don't like it, leave it aside and let us endure the financial burden. Note that the 'pay-per-use' is only for existing AOMS customers who already have the AOMS TOT processing/conversion software. You need to email us a sample CNC milling file, so we can output our new milling file according to your CNC machine setup. For other customers, we could not afford to set up a CNC system with 'pay-per-use'.
Traditional CAD/CAM software used to cost around $10,000. Now you can try it free and 'pay-per-use'. Since we include a couple of sample 3D files in the package, you don't have to spend a penny to test it on your computer and CNC.
Besides the free trial of CNC milling, we add a bonus deal in the package. On top of the CNC milling capability, we give you a 3D-printing capability with the package. It is a simple function and you can create a simple orthotic shell in STL format, based on the 3D image you scanned.
We had a dream at Sharp Shape. This dream started some 30 years ago. We wished we could mill out a foot cast without modification. Although we have tried many things, it turned out to be a hard task. In practice, our wish is a rather challenging task as the available point clouds always have some noise (like outliers) or deformation. During scanning, noise gets in the 3D data and you cannot use the data directly in milling.
In many orthotic labs, they have this type of cast correction. Some orthotic labs call it 'As-Is', because almost no cast correction, such as medial fill or lateral fill, is added. Some labs call it a 'Wash', because the positive cast is washed by hand in a basin. No matter what it is called, it represents a need. We call it 'As-Is' in our CAD/CAM work. Among the many foot cast modifications in our AOMS software, 'As-Is' turns out to be the hardest one in our AOMS systems. Only recently we are able to mill the 'As-Is' cast correction in our software product line.
The working process of the AOMS TOT CNC is shown below. The purpose of the AOMS TOT CNC approach is to carve out 'As-Is' positive foot molds on a CNC machine.
1. Scan feet with AOMS TOT sr app and XYZ files are generated. This step is taken on an iPhone or iPad.
2. Process the XYZ files with AOMS TOT processing/conversion software. Making proper alignment of the foot is critical to the success of the AOMS TOT CNC. This step is taken on a PC. Many of our customers are familiar with this step. An intermediate file called S3D is generated during this step.
3. Make 'As-Is' foot molds in the AOMS TOT CNC software. This step is taken on the same PC which is involved in the Step #2. This program reads the S3D files to make the 'As-Is'. There are details involved in this step and our instructions will tell you how. An intermediate file called SRF is generated at this step.
4. Schedule the SRF files for milling. This step is taken in the same program mentioned in the Step #3. The milling path of a foot mold is helical (spiral).
5. Feed the milling files to your CNC machine. Positive foot molds are carved out.
6. After the mold is milled out, check it against the foot that has been scanned. If that is not possible, check the measurements and shape, at least. If necessary, make changes in the next run.
Add padding to compensate for foot plantar calluses - a case study on the AOMS TOT CNC. We scanned a foot with a callus on the plantar surface. In order for the callus to show on the 3D image, we put a foam pad on the callus. The 3D image of the foot is shown on the left side in the following picture. The callus can be seen in the image as pointed by the blue arrow. Then we loaded this 3D image file to the AOMS TOT CNC software. We made an As-Is design. The design was mainly made on the adjustments of the boundary shape. The callus is shown in the middle of the following picture. The callus can be seen in the design as pointed by the red arrow. Then we carve out the positive cast. The callus is still visible in the milled positive cast. The callus can be seen on the mold as pointed by the red arrow.
This achievement benefits from our recent scanning technology development, especially the AOMS TOT sr app. The 3D data generated from it can be very dense and smooth. But still, the 'As-Is' milling requires good scanning skill no matter how good the scanning app is. If not scanned properly. the final product through the system can be a failure, namely 'garbage in and garbage out'. So let's see how good we can achieve from the new system called AOMS TOT CNC.
The CNC milling process. As we did before, we can mill wood positive molds, EVA insoles, and polypro orthotics. At this stage, the AOMS TOT CNC is in beta testing period. We only mill positive molds now. If you are not sure, you may wait until the technology becomes mature. If you are interested in it, please contact us through email.
The following videos shows how a cast is milled out. Note that this is an R&D run. The material does not have to be foam. The material is usually MDF board in production. The number of mold does not have to be a single one. Depending on the X-Y travel of your CNC machine, multiple molds can be carved out at one time. Note that the CNC machine has to be properly set up for the milling. The tool path generated from the CAD/CAM program should match the setup. The proper setup ensures that the ball-nose end mill goes directly to the center of the mold, not anywhere else. The proper setup also ensures that the milling cutter does not go into the mill table. Toching the mill table either damages the cutter or the mill. Improper CNC setup may cause damages and injuries.
Why the concept of AOMS TOT CNC works? Now let's go back to the drawing board to see how this type of cast correction is implemented by hand in a traditional orthotic lab. It will help us to figure out a way to duplicate or to mimic 'As-Is' cast correction on a computer.
Labs need to pour plaster slurry into the negative foot cast. Then a positive cast is made. No matter how the positive cast is cleaned, like sanding or washing, the next step is to apply heated plastic on top of the smoothed mold. When labs doing that, they put a layer of something, such as a rubber sheet or a piece of thick cloth on top of the mold. Some labs call the material 'diffuser'. This layer of material serves as a uniform expansion to the orthotic. Remembering this point will help us to implement it in our software.
Note that all plastics have some kind of memory. They tend to go back to its original shape after heat is dissipated. In reality, this creates a less aggressive foot arch on 'As-Is' orthotics when it is made by the traditional method.
To mimic all of the above, our program allows the user to use someone of 'diffuser' expansion or to compensate plastic-memory loss. Through out our research and development so far, we are able to mill out positive casts through the new system called AOMS TOT CNC. It is a simple approach. You or your clients need to use AOMS TOT sr to make scans. Then the scans are fed into our processing software. After doing the CAD/CAM work, milling path is created. Then the milling path is fed to your CNC machine to get the positive mold. Thanks to the newer technologies.
Notes:
Please note that this application heavily relies on the good quality of the 3D data. So you may ask your clients, the iPhone/iPad users, to take good quality scans. If necessary, training needs to be implemented.
Please also note that the orthotics coming from CNC milled positive molds and the orthotics coming from direct milling are labeled and priced differently by Medicare. You may need to consult Medicare for details.
If you need anything, Contact Us.
Privacy information about this app can be found from: Sharp Shape Privacy Page.
Contents on this page are subject to change without notice. Please visit again to check the latest update. Updated on March 27, 2025
Company website:
www.sharpshape.com
Copyright (C), Sharp Shape 2024
All rights, including photographic, polygraphic, and materials are reserved.
AOMS® is a registered trademark of Sharp Shape.
Sharp ShapeSM is a registered service mark of Sharp Shape.