The Future of Orthotics Production

Combining LutraCAD’s cutting-edge insole and orthotics software with Mosaic’s hardware solutions to modernize the workflow for labs and practitioners 

Up until now, the process of creating custom orthotics has been a laborious and time consuming practice. Practitioners work from casts and molds created from each patient to produce unique parts which must then be milled, ground, and precisely adhered together in layers. The amount of time and specialization required has limited both the quality and output of orthotics, resulting in increased costs for practitioners and longer wait times for patients. In order to combat these inefficiencies, companies have turned to additive manufacturing to enable the production of custom orthotics at scale.

Mosaic Manufacturing has advanced its groundbreaking multi-material 3D printing technology into a comprehensive ecosystem of supply chain solutions. At the heart of this ecosystem is Array, Mosaic's flagship automated additive manufacturing platform. Array empowers businesses to scale high-volume custom part production with unmatched flexibility and cost efficiency. By bringing production closer to the point of need, Mosaic helps companies transition seamlessly to future-ready operations that lower part costs and amplify their competitive edge.

LutraCAD, a Netherlands-based insole design software company, has partnered with Mosaic to revolutionize the orthotics production process. LutraCAD’s intuitive software integrates seamlessly with the Array ecosystem to create a powerful end-to-end solution. This collaboration empowers orthotics manufacturers like Ontario-based Premier Orthotics Lab (POL) to gain a competitive edge by delivering superior custom insoles with unmatched comfort and faster turnaround times.

A New Process for Orthotics Production

The traditional method of orthotics production poses inefficiencies that often result in long wait times for patients who require custom insoles for daily comfort and pain management. It begins with a clinician scanning the patient and sending their scans to the orthotics lab, who will then use the data to fabricate the orthotics by hand. The process of forming each piece of an insole is highly technical and can produce inconsistent results, as each laborer has their own approach to construction. Additionally, practitioners are limited by a narrow material selection, which can compromise comfort level. 

By combining their technologies, Mosaic and LutraCAD have unlocked a faster, more modernized process for orthotics manufacturing. Instead of cycling files back and forth between practitioners and labs, and relying on skilled labourers to craft insoles by hand, with Array and LutraCAD, production can be digitally managed by one user to produce quick, consistent, high-quality results. 

An Improved Workflow Overview

LutraCAD’s design software offers step-by-step instructions for users, making it an accessible solution for all skill levels. After uploading the patient scan, manufacturers are able to easily fine-tune each layer of the insole before production, making changes as needed. Once the designing process is complete, the file can be directly uploaded to Canvas – Mosaic’s factory-connected additive software solution – where it is sliced and sent to Array for production. From within Canvas, users are able to customize materials and print settings, as well as manage their print queue, allowing them to prioritize orders as they come in. The ability to manage the scanning and designing process digitally – via software that seamlessly integrates with one another – frees up technicians to process more patient orders.

With its four Element 3D printers and integrated robotics system, Array has unlocked unparalleled efficiency for additive manufacturing. When prints are completed, they are automatically moved to Array’s removable storage cart, allowing new jobs to begin without the need for manual changeover. For orthotics practitioners, Array enables the ability to produce insoles outside of working hours, while simultaneously reducing the demand placed on skilled labourers. Prints can be initiated from anywhere in the world, enabling up to 72 hours of uninterrupted, lights-out production for maximum efficiency and flexibility. 

When compared to traditional production methods, additive offers another key advantage for orthotics manufacturers in that it produces drastically less waste. The traditional milling process involves carving out insoles from large blocks of material; as a result, about 80% of material is wasted. By contrast, Mosaic’s solutions build insoles layer by layer, sparing little material in the process.

Empowering End Use Customers

For clients like Premier Orthotics Labs, this new solution has already produced impressive results. 

In my years as a pedorthist, I have finally found a product that feels soft on the foot but yet has enough support. 

Fareen Samji
CEO and Founder, Premier Orthotics Labs

With 15 years of expertise in the orthopedic industry, POL has earned a reputation for delivering market-leading orthotics. During the COVID-19 pandemic, POL faced challenges in finding skilled labor to support traditional manufacturing methods. This led them to adopt additive manufacturing as a solution — not only to address labor shortages and reduce turnaround times, but also to enhance the comfort and quality of their products. 

Discover our case study with Premier Orthotics Lab

By incorporating LutraCAD’s software in combination with Mosaic’s Array and Canvas, POL has been able to produce precise, comfortable insoles for their customers at a fraction of the cost and production time. Being able to scan and design orders within minutes, and then schedule print jobs to run overnight, has unlocked a unique advantage for the lab. By the time staff arrive the following morning, a full run of products is completed, allowing them a head start on the next day’s extensive order queue. 

The Future of Digital Manufacturing

The partnership between LutraCAD and Mosaic Manufacturing marks a significant step forward in the world of orthotics. By combining cutting-edge software with the power of additive manufacturing, labs and practitioners are unlocking new levels of throughput and efficiency, reducing overall waste and improving access to high-quality, custom orthotics for patients.

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