ArchSpline Systems

Contents

1. What Is ArchSpline?

ArchSpline is a cloud-based platform purpose-built for designing, documenting, and manufacturing custom foot orthotics. Unlike legacy systems that warp generic meshes, ArchSpline is built from the ground up on true NURBS parametric mathematics — producing smooth, analytically defined surfaces at any resolution.

From a single platform, clinicians can:

• Design custom orthotics using a clinically intuitive parametric engine
• Import foot scans from any scanner and align them in seconds
• Generate structured treatment protocols with insurance-ready documentation
• Export production-ready STL and STEP files
• Outsource design or manufacturing through the built-in marketplace
• Manage patients, cases, and billing documentation — all in one place

Built by a clinician who understands orthotic manufacturing. Designed for how clinics actually work.

2. Parametric Design Engine

The core of ArchSpline is a ground-up NURBS engine. Orthotic surfaces are generated from Coons-patch interpolation of four anatomical boundary curves — heel, medial arch, toe, and lateral border — producing clinically accurate shell geometry.

Control Point Architecture

12 anatomical Bézier anchor points define the orthotic outline — each independently adjustable with drag handles and Z-height overrides:

Heel Centre · Medial Heel · Medial Arch · Medial Forefoot · Met 1 · Medial Toe · Toe Tip · Lateral Toe · Met 5 · Lateral Forefoot · Lateral Arch · Lateral Heel

Interactive 2D Editor

• Full SVG overlay with drag-and-drop anchors and Bézier handle editing
• Pad center manipulation and dot-texture region painting
• Zoom, pan, and photo overlay with real-world distance calibration

Device Modes & Form Factors

Form factors: Full-length, three-quarter, heel-cup, and sandal.

3D Visualization

• Real-time 3D preview with orbit, zoom, and pan controls
• One-click camera presets: Top, Bottom, Left, Right, Front, Back
• Wireframe and shaded rendering modes
• Pad shadow visualization and scan mesh overlay with adjustable opacity
• 3D mesh brush tool (smooth / divot) with configurable brush size and strength
• Click-to-measure distance tool (readout in mm)

Model Validation

A real-time validation engine flags clinical and geometric issues — missing anchors, layer conflicts, out-of-range parameters — before export.

3. Clinical Prescription & Rx Corrections

Every prescription parameter is directly applied to the parametric surface — no secondary software needed.

Foot Morph Editor

A step-wise correction wizard guides per-region varus/valgus adjustments across forefoot, midfoot, and rearfoot segments (±10°) — with non-destructive preview and commit at each stage.

4. Pad & Modification System

A composable layer architecture lets you stack independently configurable modifications on the orthotic surface.

Layer Stack

Conformity Pad Custom Dot-Texture Heel-Skive

Each layer is independently configurable and rendered in priority order.

Built-In Pad Types

• Metatarsal Pad — Analytical Gaussian bump with 11 polar control points, configurable center, radius, height, sharpness, rotation, smoothness, and border falloff
• Arch Support Pad — Negative-displacement cutout with independent polar control points for arch relief
• Toe Crest Pad — Sulcus support pad behind the toes

Surface Features

• Dot Texture — Procedural raised or sunken dot arrays (grid or hex pattern) painted onto user-defined regions with configurable dot radius, height, and spacing
• Conformity Layer — Foot-scan match with adjustable intensity, smoothing, falloff, and paintable weight map
• Text Embossing — Custom text embossed on the bottom surface via rasterized UV displacement
• Border Falloff — Smooth edge blending on all pads for comfortable transitions

5. Foot Scanning & Imprint Processing

Import scans from any scanner. ArchSpline handles alignment, imprint processing, and pressure visualization automatically.

Scan Import & Alignment

• STL import — manual upload or direct load from patient case record
• Source Up Axis — Z-Up or Y-Up for scanner compatibility
• 3-Point Landmark Alignment — Pick Heel, 1st Met Head, and 5th Met Head; system auto-aligns
• Automated Best-Plane Alignment — Iterative support-plane refinement (5 iterations, 30 mm search radius)
• Manual Gimbal — Full 3-axis rotation, translation, scan inversion, and mirroring
• Direct Import — Skip auto-centering for pre-aligned scans
• Left & right bilateral sessions with full state serialization per side

Imprint Processing

• Z-ray intersection with boundary-blended per-vertex displacement
• Configurable depth offset, border width, transition width, minimum thickness
• Two-stage Gaussian smoothing pipeline
• Plantar pressure heatmap (28 × 42 grid) with clinical color mapping

Photo Overlay & Calibration

Load a foot photograph behind the 2D editor. Adjustable opacity, scale, position, rotation, mirror, and 2-point real-world distance calibration.

6. Treatment Protocol Engine

A structured clinical intake system that bridges your evaluation findings to orthotic design parameters and insurance documentation.

5-Step Clinical Intake Wizard

1. Protocol Selection — Choose from evidence-based protocol seeds (e.g., Plantar Fasciitis)
2. Diagnosis & Chronicity — ICD-10 pairing with laterality compliance
3. Contributing Mechanics — Select from 28+ biomechanical factors
4. Clinical Objectives — Define functional goals for the intervention
5. Baseline & Adaptive Suggestions — Auto-populated design parameters with evidence-based modification rules

Adaptive Rules Engine

When specific combinations of contributing mechanics are present, the system auto-suggests design modifications with clinical rationale and published evidence citations.

28+ Contributing Mechanics

Limited ankle dorsiflexion · functional hallux limitus · pronatory collapse · calcaneal varus/valgus · flat foot · cavus arch · leg length discrepancy · forefoot varus/valgus · hallux rigidus/valgus · digital deformity · PTTD · metatarsalgia · lateral ankle instability · Achilles tendinopathy · medial tibial stress · cuboid syndrome · sesamoiditis · medial knee OA · patellofemoral pain · Morton's neuroma · Sever's disease · pediatric flatfoot · intoeing · outtoeing · tarsal coalition — and more.

Doctrine Baseline

Each protocol auto-populates a complete set of geometry defaults — heel cup depth, arch fill, flanges, posting, ray cutouts, extensions, skives, and material hints — ensuring clinically appropriate starting parameters.

7. Billing & Reimbursement Assistance

Complete billing workflow built into the platform — from clinical intake to insurance-ready addendum generation.

HCPCS & CPT Code Mapping

• HCPCS: L3000, L3020, L3030, L4205, L4210 series with per-foot unit logic
• CPT: 97760 (initial orthotic management & training) and 97763 (subsequent management) with auto-generated timed-documentation language
• Payer Decision Tree: Commercial, Medicare, Medicaid, and Self-Pay coverage guidance per code
• ICD-10 Laterality Compliance: Automatic RT/LT modifier resolution
• Modifier Reference: 25, GP/GO/GN, GA, GY, KX — mapped to clinical context

Documentation Engine

• Functional limitation documentation (pain scale, standing/walking tolerance, LEFS/FAAM/Oswestry scores)
• Conservative care failure tracking (OTC insoles, shoe mods, NSAIDs, ice, PT, stretching, injections, activity modification)
• Objective exam findings (pronation, navicular drop, pain to palpation, abnormal plantar pressure, gait abnormality, ROM limitation, calcaneal valgus, etc.)
• Auto-generated medical necessity statements — condition-specific paragraphs covering impairment, failed conservative care, and coding linkage

Denial Prevention

• Denial Prevention Score: Green / Yellow / Red risk assessment (0–100) with actionable recommendations
• ABN Guidance for Medicare: Automatic advance beneficiary notice workflow
• Proof of Delivery: Structured documentation for delivery compliance

Addendum Generation

Full and design-only modes. Print-ready HTML/PDF output with treatment plans, fitting documentation (face-to-face minutes, visit type, timed billing units), and medical necessity statements.

8. Export & Production

From parametric surface to production file in one click. Watertight manifold output for 3D printing, CNC milling, and injection molding.

Export Formats

Solidification Engine

• Shell Mode: Top surface offset by uniform thickness, edge chamfer, heel post integration, toe taper — closed manifold
• Full-Body Mode: Perimeter projected to floor with draft angle, flat bottom fill — closed manifold
• Both produce watertight top + bottom + sidewall geometry

Token System

Exports consume self-design tokens with atomic server-side deduction to prevent double-spend. Token balance is managed per subscription tier.

9. Two-Sided Marketplace

Not every clinic wants to design. Not every clinic wants to print. ArchSpline connects clinics, designers, and production partners in a single ecosystem.

Design Marketplace

Clinics post design requests. Licensed pedorthists and orthotic designers accept cases, design within the ArchSpline NURBS environment, and deliver production-ready files.

Production Marketplace

Clinics post production orders with STL files. Verified labs and print farms receive manufacturing-ready geometry, set pricing, and manage turnaround times.

Key Marketplace Features

• Searchable Provider Directory — filter by type, availability, turnaround, specialty, and location
• Order Lifecycle: Open → Accepted → In Review → Revision → Completed / Disputed / Cancelled
• Physical Production Support: Material selection (TPU / polypropylene), density (soft / medium / firm), topcover add-on, shipping address
• 4-Zone Shipping Estimation: US Census region-based model with lab-configurable rates
• Tracking Timeline: Printing → In Transit → Delivered with carrier and tracking number
• In-App Messaging: Threaded conversations between clients and providers per order
• Dual Rating System: Clients rate providers; providers rate clinicians (with quality flags)
• Provider Earnings Dashboard: Revenue overview with milestone releases and payout requests
• Provider Applications: Self-service signup with admin approval workflow
• Production Payment Release: 50% on lab acceptance and 50% on clinic delivery approval

10. Patient & Case Management

A built-in patient database and full-lifecycle case management system — from intake to delivery.

• Patient Records: Name, DOB, foot size (US/EU/mm), foot width (narrow–extra-wide), clinical notes
• Case Workflow: Uploaded → In Progress → Designed → Approved → In Production → Finished → Needs Attention
• Bilateral Support: Per-case side selection (Left / Right / Both) with linked bilateral designs
• Case Versioning: Parent case ID tracking for revision history
• Scan Source Selection: Reuse scans from previous cases or upload new
• Clinical Intake Integration: Cases store full protocol data from the treatment protocol wizard
• Auto-Save to Cloud: Design files persist to patient case records automatically
• 4-Step Guided Workflow: Case Setup → Scan → Design → Export with step indicators

12. Education & Training

• Education Portal: Dedicated section with document library, video training (upcoming), and certification (upcoming)
• ArchSpline Systems: Billing 2026 — Comprehensive billing and reimbursement guide for custom orthotics
• ArchSpline Systems: Printing — Practical 3D printing workflow guide for reliable orthotic output
• Deep Linking: Direct URLs to specific education sections for easy sharing

14. “Powered by ArchSpline” Ecosystem

Partner organizations run their own branded orthotic programs on top of ArchSpline — managing clinics, providers, budgets, and marketplace access from a single dashboard.

Multi-Clinic Operations

• Clinic Registry: Create, rename, and deactivate clinic locations within your organization
• Provider–Clinic Assignment: Assign and reassign providers across clinic locations
• Wallet & Token Allocation: Centralized token balance with per-member allocation and audit trail
• Team Role Management: Clinician, Viewer, and Admin roles with real-time role changes
• Clinic Volume Tracking: Per-clinic case volume quotas and utilization monitoring
• Member Case Drill-Down: Expand any team member to view their case history and status
• Invoice History: Organization-level invoice listing with date, amount, and status
• Searchable Member Directory: Filter by role, status, and clinic with free-text search

Partner Protocols

• Custom Treatment Protocols: Partners define their own evidence-based protocol seeds, baseline parameters, and adaptive rules — available exclusively to their clinicians
• Org-Scoped Protocol Library: Partner protocols appear alongside standard ArchSpline protocols during clinical intake

Partner-Controlled Marketplace

• Marketplace Toggle: Enable or disable marketplace access for the entire organization
• Provider Whitelist: Restrict marketplace visibility to pre-approved labs and designers that the partner has agreements with
• Preferred Lab Ranking: Prioritize partner-affiliated labs at the top of search results

16. Pricing

Simple subscription tiers. Scalable production. Marketplace access included at every level.

Stripe-powered billing. Customer portal for plan changes, payment methods, and invoices. Credit packs available for marketplace purchases.

17. Get Started

Questions? Reach us at info@archspline.com