How to Design Custom Orthotics

Step-by-Step Guide for Podiatrists and Orthotists

Learn the complete process of creating custom orthotics using modern digital tools. From patient assessment to 3D printing, this guide covers everything you need to know.

The 7-Step Process

1

Patient Assessment

Begin with a comprehensive biomechanical evaluation. Examine the patient's gait, foot structure, and any existing pathologies. Take detailed measurements and note any specific requirements.

  • •Gait analysis (observe heel strike, midstance, toe-off)
  • •Foot posture evaluation (neutral, pronated, supinated)
  • •Range of motion testing
  • •Pressure analysis if available
  • •Patient history and symptoms review

Recommended Tools & Software

Scanning Equipment

  • • Structured light 3D scanners
  • • Phone-based scanning apps
  • • Desktop laser scanners
  • • Portable handheld scanners

CAD Software

  • • ArchSpline (specialized orthotic design)
  • • FreeCAD (open-source option)
  • • Blender (free 3D modeling)
  • • Meshmixer (mesh processing)

Common Mistakes to Avoid

Poor Scan Quality

Wet feet, motion artifacts, or low-resolution scans lead to inaccurate orthotics.

Incorrect Posting

Wrong posting angles can exacerbate rather than correct biomechanical issues.

Ignoring Material Properties

Different materials have different flexibilities and cushioning characteristics.

Skipping Quality Control

Always verify measurements and design parameters before printing.

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