Replace the lab · Keep the margin

$90–$120+typical variable savings per pair vs many outsourced lab invoices
70–90% marginscommonly cited on cash-pair orthotics when you keep the lab margin
Same-daydevices in-clinic vs 2–4 week lab turnaround—when printer + staffing fit

Orthotics are not a cost center—they are a high-margin clinical service when you own design + production. Numbers vary by payer mix and shop cost—use our calculators to stress-test yours.

How to design custom orthotics

Step-by-step guide for podiatrists and orthotists using ArchSpline end to end—from exam and iPhone scan through CAD, export, and QC.

The ArchSpline workflow (6 steps)

Assessment → Foot Scan 3D capture → cleanup & intake → ArchSpline CAD → STL / print handoff → quality control.

Clinical exam & mechanics

Start with the same clinical foundation you would use for any custom device: a focused exam to establish diagnosis, goals of care, and the contributing mechanics you intend the orthotic to influence. This page stays high level—your local standards of care drive documentation depth.

•History and symptoms; activity demands and footwear constraints.
•Biomechanical exam and gait observation as appropriate.
•Identify diagnosis and what you want the orthotic to load, offload, or control.
•Note contraindications, sensation, vascular status, and follow-up plan when relevant.

Tools we reference in this guide

Scan capture

• Foot Scan 3D (iPhone / iPad) — consumer app we use as a fast, low-friction mesh source when a dedicated structured-light scanner is not on hand.
• ArchSpline scanning playlist on YouTube — walkthrough of the medial-to-lateral sweep, heel coverage, and positioning tips described in step 2.

CAD, protocols & production

• ArchSpline — protocol-based generation and/or manual orthotic CAD, then STL export (and upcoming partner-printer send).
• Your slicer + printer stack — material profiles, supports, and machine QC remain in the slicer you already validate for clinical parts.

Common mistakes to avoid

Inconsistent scan posture

Changing knee angle, ankle dorsiflexion, or STJ position between visits makes “before/after” geometry comparisons meaningless.

Shipping noisy meshes to CAD

Chair legs, carpet spikes, and floating islands will fight shell offsets—trim them before you email or upload into ArchSpline.

Skipping QC because “it printed”

Verify posting, thickness, and fit intent against the approved on-screen design, not just slicer previews.

Wrong intake path

Mis-filed scans (email subject/body conventions) slow production—agree on a naming pattern with your team before you scale volume.

Ready to run this workflow in ArchSpline?

Join the Founding Beta Clinic Program and bring protocol-driven or manual orthotic CAD in-house on your own scans.

Join Founding Beta Program Home

What clinicians are saying

Feedback from podiatry and orthotic design specialists using ArchSpline in practice.

New version is amazing. You created a cool program for new feet morphology and individual insoles design! Amazing Bryan!

Sergey Aleks

Orthopedic doctor, Podiatrist, Orthotic Design Specialist