3D Printing for Orthotics & Prosthetics: Applications, Benefits, and Solutions

piocreat3d on August 20, 2025

The orthotics and prosthetics (O&P) industry is undergoing a digital revolution, with 3D printing emerging as a transformative force. By combining precision engineering, biocompatible materials, and simplified workflows, additive manufacturing offers new ways to create customized medical devices that improve patient comfort, functionality, and quality of life.

This blog explores how 3D printing is being applied across orthopedics, the benefits it delivers, and how PioCreat’s latest printer solutions are designed to meet the unique demands of the O&P field.

How Is 3D Printing Used in Orthopedics?

3D printing has expanded into nearly every area of orthotics and prosthetics. Below are some of the most common applications:

Insoles

3D-printed insoles allow for precise customization, tailored to the exact shape of a patient’s foot. Clinicians can design insoles with varying hardness levels, arch support, and ventilation structures, creating personalized solutions for foot pain relief and long-term orthopedic support.

Scoliosis Braces

Traditional scoliosis braces are bulky and time-consuming to manufacture. With 3D printing, braces can be lighter, more breathable, and anatomically accurate. Patients benefit from greater comfort and compliance, while clinics streamline their production process.

Prosthetic Sockets and Covers

A prosthetic socket is the most critical interface between a patient and their prosthesis. 3D printing ensures sockets are highly accurate and contoured to each patient’s anatomy, reducing the risk of pressure points. Custom cosmetic covers can also be printed to restore confidence and individuality.

Cranial Remolding Helmets

For infants with plagiocephaly, 3D printing allows for lightweight, breathable cranial helmets designed with exact cranial geometry. These helmets provide effective correction while ensuring comfort during critical growth phases.

Wrist and Hand Orthoses

Additive manufacturing enables the creation of lightweight and functional hand and wrist supports, providing stability and mobility while allowing breathable, open designs for improved patient compliance.

What Are the Benefits of Using 3D Printing in Orthotics & Prosthetics?

Sustainability

Traditional O&P manufacturing can be wasteful, with large amounts of excess material. 3D printing optimizes material usage, reducing waste and promoting more sustainable clinical practices.

Cost Savings

By eliminating the need for expensive molds, casts, and manual labor, 3D printing lowers production costs. Clinics can reinvest these savings into patient care or new technologies.

Simplified Workflow

Digital workflows—from scanning to design to print—remove the complexity of manual processes. This allows clinicians to easily adjust designs and iterate quickly without starting from scratch.

Time Savings

What once took weeks can now be completed in days. Patients benefit from faster device delivery, while clinics improve efficiency and capacity.

Printing Materials for Orthotics & Prosthetics

Material selection is critical for producing safe, effective, and durable O&P devices.

PP Composite for Scoliosis Braces

Polypropylene (PP) composites provide a balance of durability and flexibility, essential for scoliosis braces that must endure repeated wear. PioCreat’s PP composite has passed rigorous testing, including 5,000 opening and closing cycles, ensuring long-term performance in clinical use.

TPU for Insoles

Thermoplastic polyurethane (TPU) is widely used for insoles thanks to its flexibility, comfort, and shock absorption properties. TPU also allows for design variations in hardness, enabling clinicians to fine-tune insoles for different patient needs.

3D Printers for Orthotics & Prosthetics

PioCreat has developed specialized 3D printing solutions tailored to the O&P industry, ensuring clinicians and manufacturers have access to systems designed for medical applications.

MS01 SE: High-Temperature Pellet 3D Printer

The MS01 SE is the latest addition to PioCreat’s portfolio, specifically optimized for orthotic applications such as scoliosis corsets. With an industrial-grade nozzle temperature of up to 400°C, it can process advanced medical-grade polymers like PP composites. The large build size of 650mm ensures full-size brace production in one print. By removing unnecessary components for this focused application, the MS01 SE offers stable, reliable performance ideal for clinical environments.

IPX2: Special 3D Printer for Custom Insoles

The IPX2 is a dedicated solution for podiatrists and orthopedic shoe technologists. It combines materials, hardware, and software into one streamlined system, making it simple to produce custom insoles in-house. This reduces outsourcing costs, shortens turnaround times, and ensures patients receive precisely fitted insoles quickly and affordably.

PioCreat Unveils Advanced 3D Printing Solutions at Additive Manufacturing Expo Tokyo

piocreat3d on July 11, 2025

PioCreat, a global innovator in 3D printing technologies, participated in the Additive Manufacturing Expo Tokyo 2025, held as part of Manufacturing World Japan, one of Asia’s leading exhibitions for cutting-edge manufacturing technologies. The event brought together top-tier professionals from industries such as prototyping, product design, automotive, aerospace, and healthcare, all seeking the latest advancements in additive manufacturing.

At the heart of PioCreat’s showcase were two standout products: the G5Ultra Pellet 3D Printer and the newly launched HALOT-X1 16K Resin 3D Printer.

The G5Ultra, known for its large build volume (500×500×400mm) and high-speed pellet extrusion system, impressed attendees with its ability to reduce material costs while delivering industrial-grade precision. With a nozzle temperature of up to 420°C and compatibility with a wide range of thermoplastic pellets, the G5Ultra is optimized for prototyping, design research, and small-batch production—ideal for companies looking to innovate sustainably and efficiently.

The HALOT-X1, making its debut in the Japanese market, drew significant attention with its 16K ultra-high resolution, 92-zone intelligent exposure system, and no-leveling-required design. Engineered for consumer accessibility without compromising professional results, the HALOT-X1 represents the next generation of desktop resin 3D printing.

Throughout the event, PioCreat engaged with engineers, designers, and decision-makers, demonstrating how its solutions can drive digital transformation across industries. The company’s commitment to open material compatibility, user-friendly design, and cost-effective workflows resonated with professionals looking to upgrade their additive manufacturing capabilities.

As demand for smart, scalable 3D printing continues to grow, PioCreat remains dedicated to advancing industrial and consumer applications with its innovative technologies.

PioCreat Wraps Up I.S.P.O. WORLD CONGRESS 2025

piocreat3d on June 23, 2025

PioCreat proudly concluded a successful showcase at the 20th I.S.P.O. World Congress, held from June 16–19, 2025, in Stockholm, Sweden. The International Society for Prosthetics and Orthotics (ISPO) World Congress is a premier global event bringing together leading experts in prosthetics, orthotics, rehabilitation engineering, and related fields. With over 3,000 members across 90+ countries, ISPO fosters collaboration and innovation in restoring mobility and improving lives.

Throughout the congress, PioCreat engaged with industry professionals, clinicians, and researchers, highlighting how additive manufacturing is reshaping prosthetic and orthotic solutions. Our booth showcased advanced 3D printing applications designed to deliver precision, customization, and efficiency to the field.

We were delighted to connect with partners such as Eddi OrthoPros Lab and Foothealth UK, who joined us at the event for valuable discussions and collaboration.

Key Highlights of Our Solutions

Scoliosis Brace Production: The MS01 high-temperature pellet 3D printer demonstrated its capability to produce fully customized spinal orthotics with superior support, comfort, and fit.
Custom Insole Fabrication: The IPX2 3D printer, combined with our FS A003 foot scanner, provided a streamlined digital workflow for designing and manufacturing personalized insoles with precision and speed.
Prosthetic Sockets and Covers: Our custom-engineered 3D printed prosthetic sockets and covers deliver greater durability, comfort, and aesthetic flexibility compared to traditional methods. Material and color options allow for enhanced personalization while reducing limb wear and improving stability.

PioCreat remains committed to advancing digital manufacturing solutions that support clinicians and improve patient outcomes in prosthetics and orthotics.

How to Achieve High-Quality Prints with Pellet 3D Printers

piocreat3d on June 16, 2025

Pellet Material Testing

Purpose: Adjust nozzle temperature and flow rate for current ambient conditions to achieve better printing results

A. Determining Optimal Nozzle Temperature

Set Initial Temperature

Navigate to ‘Preheating’ Settings on the display.
Input the recommended temperatures for Hotend upper and hotend lower

pellets	Hotend upper	hotend lower
ABS	160	190
PLA	170	210
PETG-1211	180	220
PETG	200	230
TPU（1.2 1.5 nozzle）	160	190
TPU（2.0 3.0 4.0 nozzle）	170	200

Extrude Material

After reaching target temps, set the ‘distance’ to ‘5000mm’, and the ‘speed setting’ to ‘Slow’.
If the feed tube is empty: Click “Load Material”.
Then select “Extrude”.

Evaluate Extrusion Quality

Ideal Output:
Smooth, continuous flow without breaks/unmelted particles.
Strong tackiness between layers.

Minimal oozing when idle.

Temperature Adjustment

Too High: Excess oozing, rough surface texture → Lower by 5–10°C.

Too Low: Grinding noise from extruder, weak layer adhesion → Increase by 5–10°C.

Check for Moisture

Signs of Wet Filament: Popping/crackling sounds during extrusion.
Bubbles inside extruded strands.
Solution: Dry filament (or reduce temp as a temporary fix).
Image: Wet filament exhibits foamy, porous strands.

Common material drying parameters
pellets	Temp (°C)	Time (h)
PLA	50	1 to 3
PETG	60-70	2 to 4
ABS	80	2
TPU	95-110	2 to 4

Others pellet	Temp(°C)	Time (h)
ABS	80	3
PC	120	3
PC/ABS	100	3
PA6	80	3
PA66	80	3
PA66GF35%	80	3
PMMA	80	3
POM	100	3
PBT	120	3
PPO	100	3
PPS	150	3
PET	125	3
PPE	100	3

Validation Print

Print a hollow cube/cylinder in “Spiral vase”.
Use pliers to bend the model 90° — if it doesn’t crack, the temperature is optimized.

B. Flow Rate Calibration

Reference Video: Start at 0:43.

Slicing Software Techniques

A. Nozzle Selection Guidelines

Thin-Walled Models

Problem: Small wall thickness can cause over-extrusion at corners, leading to layer defects or nozzle collisions.
Solutions:
Use a smaller nozzle diameter (e.g., 2mm instead of 3mm).
Reduce ‘Perimeters’ to reduce wall layers:

Example: For a 12mm thickness shell, use:
2mm nozzle → 2 wall layers
3mm nozzle → 1 wall layer (to prevent excess material buildup).

Visual Comparison:
Left:2mm nozzle (double extrusion at corners → bulging).
Right:5mm nozzle (smooth transitions).

Holes Near Edges

Causes: Tight spacing leads to material buildup.

Solutions:
Reduce ‘Perimeters’ to 2.

Switch to a smaller nozzle.
Redesign model to increase hole-edge distance.

B. Special Model Optimization

Small Footprint + Tall Models

Risk: Bed adhesion failure at higher layers.
Fix: Apply glue stick or use a wide brim (10 times the nozzle diameter).

Steep Overhangs (Drooping)

Partial Solutions:
Enable dynamic overhang speeds

Increase cooling fan speed (navigate to: ‘Adjuct’> ‘Fan’ during print).

Model Orientation

Poor (Left):Requires excessive supports, prone to dropping.
Better (Right):Optimized angle reduces supports and improves quality.

Top-Heavy Models

Stabilize with: Glue or a large brim.

Hard-to-Remove Supports

Adjust support Z-distance (increase gap between support and model).

C. Design Adjustments for Printability

Models with Minimal Bed Contact

Redesign: Add a removable base for stability (avoids messy supports).

Large, Support-Heavy Models

Split into parts, print separately, and assemble post-printing.

Irregular Bottom Surfaces

Reposition vertically + add a custom support base + large brim.

Troubleshooting Common Print Failures

Layer Separation

Causes & Solutions:

Material Runout: Check if the filament spool is empty or jammed.
Sensor Issues: Ensure the filament sensor isn’t stuck due to static electricity.
Overheating: If the upper nozzle cools too slowly, the filament may gum up.
Fix:Reduce upper nozzle temp by 5–10°C(navigate to: ‘Adjuct’ > ‘Temperature’ during print).

Over-Extrusion

Solutions:

Material-Specific Settings:
TPU/Soft Filaments:Disabled retraction (causes clogs). Minor over-extrusion is normal for pellet printers.
Retraction settings:
Use slicer’s default retraction settings for Piocreat pellets brand.
Overheating:
Fix:Reduce upper nozzle temp by 5–10°C(navigate to: ‘Adjuct’ > ‘Temperature’ during print).

Flow Rate Check:
Ensure flow calibration isn’t set too high.
Nozzle Wear:
Replace if the orifice is wider than slicer settings (e.g., 0.4mm nozzle worn to 0.5mm).

Poor Layer Adhesion

Fixes:

Increase Nozzle/Bed Temp:
Raise by 5–15°C(navigate to: ‘Adjuct’> ‘Temperature’ during print).
Drafts/Temperature Swings:
Avoid AC/fans blowing directly on the printer.

Diagonal Patterns/Wobble

Root Causes:

Tall Model Instability:
Add a large brim.

Reduce print speed by 20–30%(navigate to: ‘Adjuct’> ‘Speed-‘ during print).

Uneven Cooling:
Ensure cooling fans evenly cover the model (avoid partial airflow).
Mechanical Issues:
Tighten belts, lubricate lead screws.

Collapsing/Sagging

Improve Cooling:
Max out fan speed for overhangs (but avoid warping).

Redesign:
Add internal supports or split the model.
Supports:
Use Organic supports for complex model (easier to remove).

3D Printing Insole Customization: A Smarter Approach to Orthotic Solutions

piocreat3d on June 4, 2025

The orthotics industry is undergoing a rapid transformation. As the demand for personalized, high-performance foot care rises, 3D printing is proving to be a powerful tool in delivering efficient, accurate, and scalable solutions for custom orthotic insoles. Leveraging technologies like advanced gait analysis, foot scanning, and proprietary OEM production workflows, clinics and manufacturers can now deliver tailored insole solutions faster, more affordably, and with superior consistency.

The Need for Customization in Foot Orthotics

No two feet are exactly alike. Variations in foot arch, gait, pressure points, and structure mean that one-size-fits-all insoles often fall short—particularly for patients with specific needs related to posture, pain management, or rehabilitation. Traditional methods of custom insole production can be slow, expensive, and prone to inconsistencies.

That’s where 3D-printed orthotic insoles change the game. They offer precision, adaptability, and repeatability—hallmarks of any high-quality medical device.

From Foot Scan to Finished Product: How the Process Works

Delivering a custom-fit insole involves more than just printing a shape. It requires a full-stack approach—from biometric data capture to final finishing—each step designed to ensure clinical-grade outcomes.

1. Gait Analysis

Dynamic gait analyzers capture how a person walks, highlighting imbalances or asymmetries that could contribute to foot pain, knee issues, or back problems.

2. 3D Smart Foot Scanning

Devices like the FS A003 and FS B001 generate highly accurate 3D models of the foot. The FS A003 captures millimeter-level detail in just 5–10 seconds, while the FS B001 delivers ultra-fast, ±2–3mm precision in as little as 1.5 seconds. These scanners are especially valuable in clinical settings where time and accuracy are critical.

3. Data Analysis

Using software to analyze pressure distribution, arch type, and structural anomalies, clinicians can make data-driven decisions on support zones, material density, and geometry.

4. Custom Insole Design

With this rich dataset, CAD tools help generate a digital insole model tailored to the individual’s foot shape and biomechanical needs.

5. 3D Printing

Custom insole models are printed using specialized FDM printers like the IPX2. This machine features independent dual nozzles, allowing simultaneous printing with flexible and rigid materials—ideal for combining comfort with structural support.

6. Insole Veneer Production

Aesthetic and functional veneers—customizable by color, finish, or antimicrobial properties—are added to match the patient’s lifestyle or medical requirement.

7. Polishing and Finishing

Final polishing ensures comfort, accuracy in fit, and wearability. Each pair is finished to clinical-grade standards before delivery.

The Advantages of 3D-Printed Insoles in Clinical Practice

Unmatched Precision

Unlike mass-produced inserts, 3D-printed insoles are mapped exactly to each patient’s anatomical structure. This level of customization improves pressure redistribution, enhances stability, and reduces pain more effectively.

Durability Through Materials

Modern 3D printing materials are engineered for long-term use, combining flexibility and strength. Whether the patient is walking all day or training athletically, these insoles maintain performance over time.

Scalable and Efficient Production

What once took days or weeks can now be accomplished in hours. The streamlined digital workflow—from scan to print—reduces production times without sacrificing customization. Clinics can now offer same-day or next-day custom insole solutions.

Cost Efficiency at Scale

Thanks to OEM production systems like PioCreat, large-scale manufacturing of personalized insoles becomes feasible. This reduces per-unit cost, allowing practices to deliver premium products at a competitive price.

The Technology Behind the Solution

IPX2 FDM 3D Printer

The IPX2 isn’t just another desktop printer—it’s purpose-built for orthotic insole production. With independent dual extruders, it supports simultaneous printing of multiple material types, making it possible to create insoles with both soft zones and rigid frames in a single print.

Other key features:

Designed for flexible materials
Easy-to-use interface for clinical staff
Fast turnaround for high patient volume environments

This printer helps podiatrists and orthotic technologists scale up in-house production, reduce outsourcing costs, and maintain full control over customization.

FS A003 Smart Foot Scanner

The FS A003 offers a compact, high-speed scanning system with full 3D modeling capabilities:

Millimeter-level precision
5–10 second scan time
Seamless integration with CAD/CAM design software

It’s optimized for clinics that need consistent, high-fidelity data capture for orthotic production.

FS B001 Portable Scanner

Designed for rapid scanning in dynamic environments, the FS B001 delivers:

±2–3mm accuracy
1.5-second scanning time
Intelligent reporting on arch type, heel angle, foot length, and more

Its speed and portability make it especially useful for pediatric assessments, home visits, or sports medicine applications.

Real-World Impact

For prosthetists, orthotists, and orthopedic manufacturers, adopting a 3D printing insole solution is more than a tech upgrade—it’s a strategic shift. By combining smart scanning, AI-informed design, and additive manufacturing, practitioners gain the ability to:

Improve patient outcomes through precision-fit support
Reduce lead times and cost per unit
Eliminate inconsistencies in manual fabrication
Offer new services like same-day orthotic delivery
Expand business models into sports, rehabilitation, and wellness markets

Conclusion

3D printing isn’t just the future of orthotic insoles—it’s the present. With integrated systems like the IPX2 printer and FS series scanners, medical device professionals can deliver highly customized, clinically effective insoles at scale. For clinics and manufacturers looking to increase efficiency, reduce costs, and enhance patient satisfaction, 3D-printed insole solutions represent a clear path forward.

Ready to evolve your orthotics practice? Now is the time to step into the future—one perfectly printed insole at a time.

3D Printed Scoliosis Braces: Transforming Orthotic Care with Precision and Comfort

piocreat3d on June 4, 2025

In the evolving field of orthotics and prosthetics, 3D printing technology is redefining how scoliosis treatment is approached. Traditional scoliosis braces, while effective, often suffer from limitations in fit, comfort, and customization. Additive manufacturing introduces a powerful alternative—3D printed scoliosis braces—which promise not only better patient outcomes but also greater efficiency for medical equipment manufacturers and orthopedic professionals.

Precision Engineering with 3D Printing in Scoliosis Treatment

Scoliosis, characterized by an abnormal curvature of the spine, often requires long-term bracing, particularly in adolescents. Successful treatment hinges on three essential qualities: fit, comfort, and patient compliance. These are exactly where 3D printing excels.

With the integration of digital spine scanning and computer-aided design (CAD), orthopedic specialists can now create highly personalized orthotic braces tailored to each patient’s unique spinal anatomy. This not only enhances correction but also improves the patient’s willingness to wear the brace consistently.

The 3D Printed Scoliosis Orthotic Production Process

The workflow behind a 3D printed scoliosis brace combines digital precision with material innovation:

1. High-Precision 3D Scanning

A high-resolution 3D scanning system is used to capture the patient’s body surface geometry with accuracy. This replaces traditional casting, which can be time-consuming and prone to error.

2. Data Processing and Brace Design

Once the data is collected, software converts the three-dimensional body surface scan into a digital model. Orthopedic experts shape the brace around this model, factoring in corrective forces and patient mobility.

3. Dedicated 3D Printing

The design is then sent to a pellet-based 3D printer such as the MS 01 High-Temperature Pellet 3D Printer by PioCreat. It prints the brace using lightweight, engineering-grade thermoplastic pellets, precisely layering the structure to ensure strength, flexibility, and breathability.

4. Fitting and Adjustment

Once printed, the brace is fitted to the patient. Adjustments are minimal due to the custom nature of the process. Patients report a better experience from the start, thanks to the tailored fit.

5. Monitoring and Outcome Comparison

Orthotic teams document before-and-after results, noting spine correction progress and patient feedback on wearability, comfort, and aesthetics.

Key Benefits of 3D Printed Scoliosis Braces

1. Lightweight Yet Durable

The braces are manufactured from advanced, lightweight thermoplastics, enabling patients to move freely without sacrificing the support needed for spinal correction. Lighter braces are also easier to wear under clothing and less tiring over long periods of use.

2. Close-Fitting Plasticity

Using exact 3D spine data, the brace contours closely to the patient’s body. This custom fit ensures effective corrective pressure while minimizing discomfort. Traditional braces, by contrast, often require multiple rounds of adjustments to achieve the same level of precision.

3. Breathable and Comfortable Design

Pellet 3D printing allows the creation of ventilation patterns and mesh-like structures within the brace, reducing heat build-up and skin irritation. This improves long-term wearability and helps patients adhere to prescribed brace schedules.

4. Personalized Aesthetics

Braces can be customized in style, shape, and even color, providing a much-needed psychological boost, especially for young patients. This personalization helps transform the brace from a stigmatizing medical device into a wearable piece of identity.

MS 01 Pellet 3D Printer: Engineered for Orthotic Applications

To meet the high standards of orthotic fabrication, PioCreat developed the MS 01 High-Temperature Pellet 3D Printer, optimized for printing with high-performance medical-grade materials. This system offers unmatched flexibility and production capabilities for clinics and device manufacturers.

Key Features:

Nozzle Temperature up to 400°C: Ideal for processing engineering thermoplastics like PA, TPU, and PETG with structural and functional integrity.
Large Build Volume: 500×500×650mm allows for full-size torso braces to be printed in a single piece, eliminating weak points from part assembly.
Fully Enclosed Chassis: Maintains a stable environment, ensuring dimensional accuracy and print quality even with high-temp materials.

The MS 01’s screw-extruder design enables the use of pellet feedstocks, which are more affordable and environmentally friendly than filament. Clinics and labs can reduce costs while expanding material options.

Why It Matters: From Clinic to Community

For prosthetists, orthotists, and healthcare providers, the shift toward 3D printed scoliosis braces brings multiple advantages:

Faster turnaround times with digital scanning and printing
Less material waste compared to subtractive methods
More comfortable and compliant patients, leading to improved clinical outcomes
Scalable production for both small clinics and larger medical manufacturers

As the field moves forward, digital orthotics fabrication will continue to set new standards in patient care and operational efficiency.

Looking Ahead

The integration of pellet 3D printing into orthotic production not only modernizes how braces are made, but it also empowers practitioners with new tools to deliver better care. With reliable hardware like the MS 01, supported by high-precision scanning and customizable design workflows, healthcare professionals can meet the growing demand for personalized, sustainable, and effective scoliosis treatment.

In a healthcare landscape increasingly focused on patient-centered design, 3D printed scoliosis braces are more than a technological upgrade—they represent a new standard in orthotic innovation.

Interested in learning more about how pellet 3D printing can improve orthotic outcomes? Contact us to explore how the MS 01 can elevate your practice.