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Webinar Q&A

We had a number of questions asked that we did not get to fully cover in our Webinar last week. We have thus compiled our favourite questions and answers on this page. If you have any more, feel free to reach out to


Are there still breakages and is the new nylon being used yet?

We use MJF Nylon 11. There are still breakages that we experience from time to time. We find that most breakages occur when we try doing quick transitions from thick to thin areas. We are doing FEA and physical testing to minimize these occurrences but find that we are still learning all the time.


How does the cost of 3D printed devices compare to traditional plastic molded orthoses?

It's hard to directly compare, if you are trying to purely replace traditional plastic moulded manufacture with 3d print, the cost of the actual device is more expensive. But  if you see that 3D print brings aspects to the design of the device that are hard, (or nearly impossible) to achieve in traditional, then the cost is comparable. For example; often to achieve flexibility and stiffness in the one device means you are creating a double thermo forming  device (thermo forming two different types of materials)  - this is a much more labour intensive thermoforming once device.


What % of PDE's was Paul printing vs CF?

In the last couple of months I think about 20% of those orthoses so far.


Have you printed CROW's yet?

No this is not a device that we have attempted


Do you design the orthosis or does the orthotist give you the design eg . heel height, sank to vertical angle?

Workflow 1:  ??  When a modified & corrected physical cast is scanned the SVA OR the heel height needs to be specified by the orthotist. If we are in any doubt as to the required alignment we will use the digital review process to have the orthotist confirm before proceeding.


Work flow 2 : When using a full digital workflow 2 the finished modified shape needs to be aligned before it is exported so that the AA and SVA are shown in the horizontal and vertical, this determines the heel height. There are a number of features you can select from when designing the AFO when using the AbilityMade platform. 


How do you add padding?

Padding needs to be allowed for in the modification of the internal/interface shape e.g. added to the plaster model before scanned or relief given in CAD.


How thermos mouldable is the nylon product?

Heat adjusting the Nylon is not comparable to the ease of adjusting Polypropylene, it definitely needs a longer, more gentle heating process before being able to make an  adjustment.


Is this service only catering for paediatrics?

The height of the AFO is the determining factor, the print bed can print up to the size of ….cm


Can 3d printing be used for adults?

Yep! We have provided PDE orthoses for 4 adults so far and going really well


Is there a material that 3D can off as a check fit?

Currently AM has not researched or developed devices for check fits.

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