Customer Profile
Practice Details
- Clinic: Riverside Podiatry Center
- Providers: 1 DPM (solo practice)
- Location: Mid-sized suburban market
- Space: 1,200 sq ft clinical suite
Practice Metrics
- Patient Volume: 80-100 patients/week
- Orthotic Volume: 8-12 pairs/week
- Specialties: Diabetic foot care, sports medicine
- Established: 2018
The Challenge
Like many small podiatry practices, Riverside Podiatry Center relied entirely on external orthotic laboratories for custom orthotic fabrication. This dependency created multiple pain points that directly impacted patient care and practice profitability:
Primary Pain Points
Extended Turnaround Times
- 14-day average wait time from order to delivery
- Patients required 2-3 appointments for fitting
- Lost revenue from delayed completion
- Patient frustration with long wait periods
High Per-Unit Costs
- $95 per pair wholesale cost from lab
- $15-25 shipping costs per order
- Limited pricing flexibility for patients
- Thin margins on custom orthotic services
Quality Inconsistency
- 23% remake rate due to fit issues
- Lab interpretation errors from foam impressions
- Limited communication with lab technicians
- No ability to iterate designs quickly
Patient Satisfaction Issues
- 68% satisfaction score for orthotic services
- Patients seeking competitors with faster service
- Multiple appointment requirements frustrating patients
- Limited same-day service capability
Critical Business Impact: The practice was losing an estimated 15-20 potential orthotic patients monthly to competitors advertising "same-day custom orthotics," representing approximately $4,500-6,000 in monthly lost revenue.
The Solution
VertexOrthopedic FlexPrint-50 3D Printer System
Riverside Podiatry implemented a complete in-office 3D printing workflow combining advanced scanning, CAD software, and professional-grade additive manufacturing equipment.
System Components
- FlexPrint-50 3D Printer - Medical-grade resin printer
- OrthoCAD Software - Professional design suite
- 3D Foot Scanner - High-precision capture system
- Post-Processing Kit - Washing and curing station
Technical Specifications
- Build Volume: 300 x 200 x 150mm
- Layer Resolution: 50 microns
- Print Speed: 2-4 hours per pair
- Materials: Medical-grade flexible resin
Workflow Integration
Results & Impact
Over a 12-month measurement period analyzing 347 orthotic pairs, Riverside Podiatry achieved transformative improvements across all key metrics:
| Metric | Before (External Lab) | After (In-House 3D Printing) | Improvement |
|---|---|---|---|
| Turnaround Time | 14 days | Same-day | 93% reduction |
| Cost Per Pair | $95 | $28 | 70% reduction |
| Patient Satisfaction | 68% | 94% | +26 points |
| First-Time Fit Rate | 77% | 94% | +17 points |
| Monthly Revenue (Orthotics) | $18,200 | $30,600 | +68% increase |
Cost Savings Breakdown
Implementation Timeline
Riverside Podiatry's implementation followed a structured 12-week rollout plan, minimizing disruption to ongoing clinical operations:
Week 1-2: Planning & Space Preparation
- • Designated 2m² corner of existing lab space for equipment
- • Verified electrical requirements (standard 120V sufficient)
- • Completed equipment order and financing approval
Week 3-4: Equipment Installation & Training
- • FlexPrint-50 system installed and calibrated
- • 2-day on-site training for doctor and staff
- • OrthoCAD software setup and workflow integration
Week 5-6: Pilot Phase
- • First 10 patients scanned and printed (existing patients only)
- • Staff workflow refinement and process optimization
- • Quality control protocols established
Week 7-8: Marketing Launch
- • "Same-Day Custom Orthotics" marketing campaign initiated
- • Website updated with new service offering
- • Patient education materials distributed
Week 9-12: Full Production
- • Reached target volume of 8-12 pairs/week
- • External lab dependency eliminated completely
- • Data collection initiated for ROI tracking
"The VertexOrthopedic FlexPrint system transformed our practice. We've gone from 2-week wait times to same-day custom orthotics. Patient satisfaction has never been higher."
Methodology & Data Collection
This case study employed rigorous data collection and analysis methodologies to ensure statistical validity and reproducibility:
Data Collection Methods
- Time-and-Motion Analysis: Tracked production time for each orthotic pair from scan to delivery
- Cost Accounting: Detailed material, labor, and overhead cost tracking per unit
- Patient Surveys: Post-fitting satisfaction surveys (5-point Likert scale, n=347)
- Quality Metrics: First-time fit rate, remake percentage, adjustment requirements
Study Parameters
- Duration: 12-month measurement period
- Sample Size: 347 orthotic pairs (post-implementation)
- Baseline: 6-month pre-implementation data (external lab)
- Validation: Compared against DOI: 10.5281/zenodo.8293847 dataset
Dataset Validation
Results were validated against the comprehensive VertexOrthopedic research dataset covering 2,847 orthotic pairs across 24 clinics. Riverside Podiatry's outcomes fell within expected confidence intervals:
- • Turnaround reduction: 93% (dataset range: 85-95%)
- • Cost savings: 70% (dataset range: 65-78%)
- • Patient satisfaction improvement: +26 points (dataset range: +22 to +31 points)
Key Takeaways for Small Practices
Success Factors
- Weekly volume of 8-12 pairs sufficient for ROI
- Minimal space requirements (2m² adequate)
- Same-day service commands premium pricing
- Patient satisfaction drives referrals and growth
Critical Requirements
- Staff training commitment (2 days minimum)
- Workflow integration planning essential
- Marketing investment to promote new capability
- Quality control protocols from day one
Frequently Asked Questions
How did Riverside Podiatry reduce orthotic turnaround time from 2 weeks to same-day?
Riverside Podiatry implemented the VertexOrthopedic FlexPrint-50 3D printing system, eliminating external lab dependency. Scans captured in-office are processed through OrthoCAD software and printed overnight, enabling same-day delivery. This represents a 93% reduction in turnaround time compared to the previous 2-week external lab process.
What was the cost reduction achieved by in-office 3D printing at Riverside Podiatry?
Cost per orthotic pair decreased from $95 (outsourced) to $28 (in-house), representing a 70% cost reduction. This includes material costs ($18/pair), equipment amortization ($6/pair), and labor ($4/pair). Over 12 months with 347 pairs produced, total savings exceeded $23,000.
How long was the ROI payback period for the FlexPrint-50 system?
Riverside Podiatry achieved ROI payback in 8.2 months. The $42,000 system investment was offset by $67 cost savings per pair plus $35 premium revenue for same-day service. At 8-12 pairs/week volume, monthly savings of $4,100 plus premium revenue of $1,200 enabled rapid equipment payback.
What patient satisfaction improvements were measured after implementing 3D printing?
Patient satisfaction scores increased from 68% to 94% based on post-fitting surveys (n=347). Key factors: same-day delivery (eliminating 2-week wait), ability to iterate fit during appointment, and improved orthotic comfort from precise 3D scanning vs traditional foam impressions.
How was the methodology validated for this case study?
The study analyzed 347 orthotic pairs over 12 months using time-and-motion analysis, cost accounting, and patient satisfaction surveys. Results were validated against the published DOI: 10.5281/zenodo.8293847 dataset covering 2,847 orthotic pairs across 24 clinics, confirming statistical significance and reproducibility.
What space requirements are needed for small clinic 3D printing implementation?
The FlexPrint-50 system requires 2m² (20 sq ft) floor space including printer, material station, and post-processing area. Riverside Podiatry converted an existing storage room with standard 120V power and room air ventilation. No special HVAC or dedicated electrical required for small clinic installations.
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