We now choose 3D-printing as standard for all our lab-made devices for 2 big reasons:
By printing a device from scratch, we are not tethered to the limitations of traditional manufacturing techniques. New design features allow us to incorporate stiffening or flex zones across the shell of a device so the resistance changes at different points. As Podiatrist with in-depth knowledge of foot mechanics, we get very excited about this as it allows us to alter the loading of joints, tendons, ligaments and muscles with a level of precision that was out of our reach before now.
3D-printing has also completely changed the environmental impact of foot orthoses for the better. Something we all must take very seriously. Traditional manufacturing techniques involve milling large blocks of plastic down the required shape and discarding of the remaining material - usually in excess of 80% waste! By building a device from scratch using only the material needed, there is minimal excess/waste material - now less than 4% and improving all the time.