Custom Foot Orthotic

Collaborators: Stanford Orthopaedic Surgery

In one complex Orthopaedic Surgery case, a patient required a custom orthotic following tumor resection and reconstruction. Because the postoperative anatomy was highly unusual, traditional prosthetic and orthotic providers were unable to design an orthotic that fit appropriately or provided the support needed for walking.

Forced to explore alternatives, Orthopaedic Surgery created a 3D surface scan of the foot and began seeking internal collaborators who could help develop a custom solution. The scan captured the patient’s postoperative anatomy, but translating that data into a functional orthotic required specialized design and prototyping expertise.

Figure A: 3D rendering of the orthotic design.

Figure C: In-house 3D printed prototype, produced in TPU.

The 3DQ Lab used the surface scan as the foundation for a digital orthotic design. After review and approval by the clinical team, the device was manufactured and fitted to the patient. Early versions were produced by an outside vendor to explore material properties; later iterations were manufactured in-house as the design  continued to evolve over the past six years.

This case highlights how patient-specific design can provide solutions when standard options are not feasible. Faced with a uniquely challenging reconstruction, the 3DQ Lab was able to develop a custom orthotic tailored to the patient’s anatomy and functional needs.

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