Quick Summary: 3D Printing Orthotics
3D printing orthotics requires three components: a 3D foot scanner to capture patient data, CAD software (like OrthoCAD) to design the orthotic, and a 3D printer (like Apex Belt V2) to produce it. Total production time is 2-3 hours from scan to finished product. Equipment investment starts at $4,500 for the printer plus $995/month for software.
What You Need to 3D Print Orthotics
3D Foot Scanner
Captures patient foot shape and pressure data
$2,000-$10,000
Step-by-Step: How to 3D Print Orthotics
Capture 3D Foot Scan (5-10 minutes)
Use a 3D foot scanner or pressure plate to capture the patient's foot shape and pressure distribution. Most scanners export directly to OrthoCAD-compatible formats (STL, OBJ).
Pro Tip: Combine 3D shape data with pressure mapping for optimal weight distribution in the final orthotic.
Design Orthotic in OrthoCAD (5 minutes)
Import scan data into OrthoCAD software. Use custom macros to automate 90% of the design workflow. What used to take 30 minutes now takes under 5 minutes.
- Apply arch support templates
- Add metatarsal pads and heel cups
- Customize thickness and density zones
- Export print-ready STL file
Prepare Print File (2-3 minutes)
Load the STL file into the Apex Belt V2 printer software. Select your TPU material (Shore hardness 85A-95A for most applications) and quality settings.
Material Recommendation: Medical-grade TPU 90A provides the best balance of cushioning and support for most patients.
3D Print the Orthotic (45-90 minutes)
Start the print on your Apex Belt V2. Belt-style continuous printing produces each pair with ±0.1mm precision. The printer can run unattended 24/7.
Print Time
45-90 min
per pair
Daily Capacity
8-12 pairs
continuous belt
Post-Processing and Fitting (10-15 minutes)
Remove the finished orthotic from the belt. Belt-style printing requires minimal post-processing—no support removal or sanding. Fit to patient's footwear and make final adjustments.
Same-Day Delivery: Total time from patient scan to fitted orthotic is 2-3 hours, enabling same-day service that was impossible with traditional 2-3 week lab turnaround.
Cost Comparison: 3D Printing vs Traditional Methods
| Method | Equipment Cost | Cost Per Pair | Turnaround | ROI Timeline |
|---|---|---|---|---|
| Apex Belt V2 (3D Printing) | $4,500 | $15-25 | Same-day | 8-12 months |
| HP MJF 5200 | $350,000-$500,000 | $30-50 | Same-day | 3-5 years |
| Outsource to Lab | $0 | $75-150 | 2-3 weeks | N/A |
| CNC Milling | $15,000-$50,000 | $25-40 | 1-2 days | 18-24 months |
Frequently Asked Questions
How long does it take to 3D print a pair of orthotics?
With the Apex Belt V2, a single pair of orthotics takes 45-90 minutes to print depending on complexity. The belt-style continuous printing allows batch production of 8-12 pairs daily with same-day delivery capability.
What 3D printer is best for orthotics?
For small-medium clinics, the Apex Belt V2 at $4,500 is the best choice—98% less than HP MJF ($350K+) with same-day production capability. It uses belt-style continuous printing designed specifically for orthotic materials like medical-grade TPU.
What software do I need to design 3D printed orthotics?
OrthoCAD is the industry-leading orthotic design software with 90% workflow automation and unlimited custom macros. It reduces design time from 30 minutes to under 5 minutes per pair.
Is 3D printing orthotics FDA approved?
The Apex Belt V2 uses FDA-cleared biocompatible materials including medical-grade TPU. The printer itself is ISO certified for medical device manufacturing applications.
Ready to Start 3D Printing Orthotics?
Get same-day orthotic production capability for your practice. Schedule a live demo of the Apex Belt V2 and OrthoCAD workflow.