What materials are best for 3D printing orthotics?

Biocompatible TPU resin (Shore A 85-95) and flexible photopolymer resins are best for orthotic 3D printing. These materials offer the right balance of flexibility, durability, and skin safety required for custom foot orthotics.

Are 3D printing materials for orthotics FDA approved?

Yes, biocompatible resins used for orthotic 3D printing are FDA-approved for medical device manufacturing and direct patient contact. Materials must meet ISO 10993 biocompatibility standards.

How much do orthotic 3D printing materials cost?

Biocompatible orthotic resins typically cost $45-65 per kilogram, with material cost per orthotic pair ranging from $2-4 depending on size and thickness requirements.

Orthotic 3D Printing Materials Guide

Comprehensive guide to biocompatible materials for orthotic 3D printing including resin properties, FDA compliance, cost analysis, and material selection criteria for professional applications.

12+

Material Options

FDA

Approved

$2-4

Cost per Pair

Orthotic 3D Printing Material Categories

Understanding material properties and applications for different orthotic requirements

Flexible Materials

Soft, cushioning materials for accommodative orthotics and comfort applications

TPU Flexible Resin

Shore Hardness: A 85-95

Elongation: 200-400%

Cost: $55/kg

Applications: Soft orthotics

Elastic Photopolymer

Shore Hardness: A 70-85

Elongation: 150-300%

Cost: $48/kg

Applications: Cushioning insoles

Medical Silicone Resin

Shore Hardness: A 60-80

Elongation: 400-600%

Cost: $72/kg

Applications: Diabetic insoles

Rigid Materials

Hard, supportive materials for functional orthotics and structural support

Rigid Orthotic Resin

Shore Hardness: D 80-90

Flexural Strength: 120 MPa

Cost: $45/kg

Applications: Functional orthotics

Carbon Fiber Reinforced

Shore Hardness: D 85-95

Flexural Strength: 180 MPa

Cost: $85/kg

Applications: Athletic orthotics

Biocompatible Nylon

Shore Hardness: D 75-85

Flexural Strength: 95 MPa

Cost: $52/kg

Applications: Pediatric orthotics

Material Selection Matrix

Choose the right material based on patient condition and orthotic requirements

Condition/Application	Material Type	Recommended Material	Shore Hardness	Cost/Pair
Plantar Fasciitis	Semi-Rigid	TPU Flexible Resin	A 90-95	$3.20
Diabetic Foot Care	Soft	Medical Silicone Resin	A 60-70	$4.15
Athletic Performance	Rigid	Carbon Fiber Reinforced	D 85-90	$4.90
Flat Foot Correction	Rigid	Rigid Orthotic Resin	D 80-85	$2.60
Heel Spurs	Soft	Elastic Photopolymer	A 75-80	$2.85
Pediatric Orthotics	Semi-Rigid	Biocompatible Nylon	D 75-80	$3.00

FDA Compliance & Material Safety

Understanding regulatory requirements and biocompatibility standards

FDA Class I

All orthotic materials meet FDA Class I medical device requirements for direct patient contact

ISO 10993

Biocompatibility testing including cytotoxicity, sensitization, and irritation assessments

USP Class VI

Materials certified for extended skin contact applications up to 30 days continuous wear

Material Safety Guidelines

Pre-Processing Safety

• Store resins in dark, cool environments (15-25°C)
• Use proper ventilation when handling liquid resins
• Wear nitrile gloves and safety glasses during setup
• Check material expiration dates before use

Post-Processing Requirements

• Complete alcohol wash cycle (99% IPA, 5 minutes minimum)
• Full UV curing as per material specifications
• Remove all support material residue completely
• Visual inspection for surface defects or contamination

Material Cost Analysis

Understanding material costs and production economics

Material Costs Breakdown

TPU Flexible Resin (per kg): $55

Rigid Orthotic Resin (per kg): $45

Medical Silicone Resin (per kg): $72

Carbon Fiber Reinforced (per kg): $85

Average material per pair: 45-65g

Production Economics

$2.60

Average Material Cost per Pair

Based on 55g average material usage

1kg

Makes 18-22 pairs

Material waste rate

Monthly Production (100 pairs):

$260-320 in materials