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Stratasys Advances Custom Foot Orthotics with Large-scale 3D Printing

Published on 2017-05-05. Author : SpecialChem

3D Printing for Patients
VALENCIA, Calif. -- Millions of people worldwide are impacted by debilitating foot pain, making it difficult to accomplish such daily activities as climbing stairs or taking a walk. Stratasys Direct Manufacturing is now collaborating with Peacocks Medical Group, among the leading medical equipment suppliers and creators of Podfo orthotics, to maximize 3D printing for large-scale production of custom orthotics. Stratasys Direct is giving millions of new patients’ access to life-changing orthotics - offering much needed pain relief and improvements in mobility.

3D Printed Podfo Orthotics


Foot orthotics is a large and growing market - with analysts estimating the insole segment reaching $3.5 billion by 2020. Conventional manufacturing processes require long lead times and are unable to cost-effectively produce advanced design elements - further creating barriers-to-adoption.
  • Aided by Laser Sintering, the Podfo line fills this void with a comfortable, tough, lightweight and thin orthoses customized to each patient's prescription and footwear. 
  • Advanced 3D printing technology enables creation of complex geometries and includes varying features within a single device - eliminating top-covers, glued-on pads or foams typically accompanying conventional methods. 

Greg Reynolds, Vice President of Additive Manufacturing at Stratasys Direct Manufacturing, said:
"Solving tough design challenges and stimulating innovation are hallmarks of our customers' success. Podfo is a perfect example of how millions around the world can now experience life-changing impacts made possible by 3D printing."

Podfo Ghost Model
Podfo Ghost Model

3D Printing Enabled Advanced Design


  • The advanced design freedom enabled by 3D printing ensures Podfo can achieve new levels of customization, creating accurately fitted foot orthotics with individually selected areas of control and flexibility. 
  • In Nylon 11, Podfo has a material perfectly suited to meet thin and lightweight functionality requirements. 
  • Material durability is tested to millions of cycles - ensuring designs retain optimum effectiveness over years of use. 

Scott Rader, General Manager of Medical Solutions at Stratasys, said:
"In a field like medicine where customization is key, our work with Podfo perfectly exemplifies how 3D printing produces highly specific solutions to improve a patient's quality of life. We're putting the power of 3D printing to work with Podfo - delivering medical solutions that significantly improve clinical outcomes of the most complex foot ailments."

Steve Cook, Business Development Director at Podfo, said:
"Backed by an unmatched global footprint and ecosystem, Stratasys Direct Manufacturing gives us a virtually unlimited global manufacturing platform fueled by 3D printing. That's a huge competitive advantage for us."

Stratasys is a registered trademark of Stratasys Ltd. and/or its subsidiaries or affiliates.

About Stratasys Direct Inc., dba


Stratasys Direct Manufacturing, is an indirect subsidiary of Stratasys Ltd., the 3D printing and additive manufacturing solutions company. Stratasys Direct Manufacturing is one of the world's largest providers of 3D printing and advanced manufacturing services utilizing the latest technologies and decades of experience. With a broad range of additive and conventional manufacturing services, Stratasys Direct Manufacturing assists companies at all stages of product development to bring better products to the market faster.

About Stratasys Ltd.


For more than 25 years, Stratasys Ltd. has been a defining force and dominant player in 3D printing and additive manufacturing - shaping the way things are made. Headquartered in Minneapolis, Minnesota and Rehovot, Israel, the company empowers customers across a broad range of vertical markets by enabling new paradigms for design and manufacturing. The company's solutions provide customers with unmatched design freedom and manufacturing flexibility - reducing time-to-market and lowering development costs, while improving designs and communications.

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Source: Stratasys Ltd.
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