Step 1 : Biomechanical Assessment

The first step in a digital process is the biomechanical assessment. This is done with the use of a biomechanical plate. Plates come in various sizes from 0.5m to 3.2m and from various manufacturers (Sensor Medica, Medicaptuers, TekScan, Rs Scan, Zebris, Novel). Our only requirement is the practitioner must have one, and he needs to use the plate to evaluate his patients biomechanical differences.

You walk or stand on the plate and it measures your pressure, gait, stride length etc.

Once the practitioner has completed the assessment, the plate data is exported so it can be used when designing your orthotic.

Step 2 : 3D Foot Scan or Foam Box Scanner

The 3D foot scan allows the practitioner to take an accurate image of your foot. The process takes 4-5 seconds per foot and the image is converted into a 3D mesh of your foot. This step alone saves the practitioner 15 minutes as the old methodology required them to use plaster of paris to mould your feet.

The foot scan is optional as the CAD CAM software is capable of using just the plate data in the design of an orthotic.

While the 3D scanner is optional we do recommend it as it gives a more accurate design.

Step 3 : CADCAM Design

Step 4 : Manufacturing

Manufacturing takes between 3.5 and 10 minutes for the milling machine to manufacture a pair of orthotics.

This is the final step in the process. The milled pair is removed from the machine, then cut out from the blank and a technician grinds and sands the pair until smooth. They prepare the orthotic so it will easily fit into your shoe.

Step 5 : Finishing and fitting

Once all the data has been captured and the practitioner knows what corrections to make, the orthotic design process can begin. With the digital data imported, adaptations and corrections to your orthotic to within 0.1mm can be made, allowing for a greater level of control and accuracy.

Computer aided design (CAD) technology is used to perform precision corrections. This technology replaces manual plaster work while still servicing traditional prescription variables. Our Practitioners gather your biomechanical information through the use of a Biomechanical plate and they scan your foot digitally with an SLS 3D scanner or 3D Foam Scanner. This information is combined in the CAD software to generate a  “virtual positive”. Your prescription variables are applied to the “virtual positive” and computer aided manufacture is utilized to produce custom orthotics to your exact design specifications.

Once the design process is complete the finished file is sent to the milling machine to manufacture your individual pair of orthotics in under 30 minutes.

What are Digital Orthotics?