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We explore how foaming TPU, belt printers, and clinician-led automation can bring custom foot orthoses in-house, cut costs, and reduce lead times from weeks to hours. Fredrik from CADmed shares what actually works, what doesn’t, and how remote design plus per-pair pricing changes the game.

• why automation increases clinician control rather than removes it
• carving versus printing tradeoffs on speed, finish, and cost
• foaming TPU benefits including smoother surfaces and less waste
• belt printers for continuous TPU production and better surface feel
• FDM advantages over powder bed fusion for insoles
• practical lattices and gradients without overengineering
• decentralizing production to clinics for faster delivery
• remote design, slicing, and printer control with per-pair pricing
• scaling systems for reliability, repeatability, and low friction

Special thanks to Advanced 3D for sponsoring this episode.

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We trade trade-show gloss for real-world tactics, then lay out a three-step plan to bring 3D printing into O&P without risking patient care or cash flow. From Bambu-level starters to automated check sockets, we show how to start lean, learn fast, and scale what works.

• Formnext’s shift from machines to applications
• Materialise Bricks for modular workflows and costing
• Multi-material metal, gradient parts, and smarter tooling
• Affordable LPBF and the desktop print farm surge
• Start with a low-cost printer and print clinic tools
• Outsource complex adjustable sockets to free capacity
• Automate transtibial check sockets for speed and margin
• Scanner choices from budget to pro with trade-offs
• A three-tier roadmap to adopt and scale digital O&P

Special Thanks to Advanced 3D for sponsoring this episode.

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We record on the road to the mothership to fit a 3D-printed adjustable suction socket using AirFit casting and compare loaded scans to raw scans. David shares his crash-to-career journey, why adjustability matters for neuromas and daily volume, and what makes the Americus foot feel lighter and livelier than it looks.

• AirFit casting under load versus direct scanning
• Four-scan workflow and remote 3D fabrication
• Suction plus adjustability for volume and hotspots
• Flexible inner swaps for quick tuning
• David’s neuroma history and fit lessons
• Americus foot layup, split keel, and energy return
• Social media as connector, career builder, and patient support
• Choosing a prosthetist who listens and offers trials
• Safety, waste, and smarter ovens in the lab
• Why 3D printing speeds care and improves revenue cycle

Find David: YouTube The Adventurous Amputee • LinkedIn David Slider • Instagram Pirate Peg Leg and The Adventurous Amputee

Special thanks to Advanced 3D for sponsoring this episode.

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