Slow and Inconsistent Orthotic Workflows

In many central fabrication labs today, traditional modification workflows still dominate. While they get the job done, these methods are manual (often taking around an hour per case) and difficult to standardize across a team. This inconsistency makes it difficult to maintain quality. For orthotists, clinic managers and even central fabricators , this creates a constant tension between providing excellent patient care and finding enough time to scale their practice or labs.  

The rise of digital tools promised relief but in practice, many solutions like Meshmixer have proven time-consuming for orthotic workflows. These tools may speed things up from traditional modifications, but outcomes may vary from one technician to another – leading to frustration, rework and uncertainty. This leaves many fabricators and clinicians stuck between inefficiency and inconsistency, a reality that’s unsustainable for clinics looking to grow.  

Real progress requires tools that are efficient, repeatable and clinically proven. The answer lies in technology built specifically for orthotic workflows - solutions that bridge the gap between speed and consistency, without compromise.  

This is the landscape Certified Orthopedics set out to change.

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Who is Certified Orthopedics?  

Certified Orthopedics is a leading provider of fabrication and patient care services, working with patients and referral partners to design and deliver devices that improve mobility and quality of life. Their clinic offers a full range of orthotic and prosthetic services, from patient assessments and casting to fabrication and fitting.  

Over the years, they’ve earned a reputation for being ahead of the curve in digital transformation – at a time when many clinics still rely on manual workflows or generic digital tools. They’ve positioned themselves as a tech-advanced partner, proving that innovation can go hand-in-hand with outstanding patient care.  

Their approach is simple but powerful: deliver consistent, high-quality outcomes while building the operational efficiency needed to provide custom devices at scale. For referral partners, this means confidence that patients will receive the same standard of care every time. For clinic managers and orthotists, it’s proof that embracing new technology isn’t just about keeping up – it's about leading.

By adopting footForma, Certified Orthopedics demonstrates what’s possible when a lab commits to working smarter, not harder. And for others in the field, the signal is clear: if an industry leader like Certified Orthopedics trusts this technology to scale and strengthen their practice, it’s worth a closer look.  

But even a forward-thinking clinic like Certified Orthopedics wasn’t immune to the challenges of inefficient workflows.  

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The challenges they faced

As their clinic grew, the time burden and lack of standardization became an obstacle to quality and scalability.

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“I talked to my guy in the plaster room, and he says that pouring and hand-modifying the plaster on an AFO mold will take him anywhere from 40 minutes to an hour. Modifying a foam mold takes him 15-20 minutes. So, the time savings for him are huge. But most importantly, we are eliminating the inconsistencies of hand-modifying,” said Chase Bradshaw, CAD/CAM Designer at Certified Orthopedics.

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Turning to digital alternatives seemed like the logical next step. Tools such as Meshmixer promised efficiency, and in some cases, they did reduce modification times, but these programs were never designed for orthotics. They lacked the precision and consistency required in clinical practice, which left results dependent on the individual clinician or technician’s skills and workarounds.  

The consequence? They had no reliable way to ensure that every designer on the team could produce the same high-quality outcome. For a practice like Certified Orthopedics – one that takes pride in efficiency, patient care, and their reputation with referral partners – this was a point of frustration.  

Recognizing these limits, Certified Orthopedics looked for a solution designed specifically for orthotics.  

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The solution: Adopting footForma

When it became clear that manual methods and generic digital tools weren’t enough, Certified Orthopedics turned to a solution designed specifically for their field: footForma. Unlike general CAD software, footForma aligns directly with the needs of clinicians and technicians rather than forcing them to adapt to workarounds.  

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The improvements were clear from the start, footForma was designed to:  

• Cut modification times significantly.

• Deliver repeatable results every time.

• Provide specialized features tailored to clinical design.

• Make daily workflows intuitive and easy to integrate.

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For Certified Orthopedics, this meant more than just speed. With footForma, they could ensure standardized, high-quality modifications across their team and give every technician the ability to produce consistent results. Just as importantly, the added efficiency freed up valuable time to focus more on complex cases instead of struggling with inefficient or unreliable tools.

By integrating footForma, Certified Orthopedics not only solved their immediate workflow challenges – they also positioned themselves as tech-advanced practice ready to scale. For referral partners, this level of repeatability means confidence that every patient receives the same standard of care, no matter which clinician is involved.  

Furthermore, the measurable results proved just how transformative the change would be.

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Results with proof  

The results speak for themselves:  

• Manual workflows: ~1hour hand-modifying per orthotic modification.

• With footForma (including carving time): 40-45 minutes – a meaningful gain for busy clinics.

• With Meshmixer: modifications took 15-25 minutes, but outcomes varied depending on the clinician.  

• With footForma: that same process takes up to 10 minutes with reliable results across the team.  

"From start to finish, hand-modifying our casts would take 50 to 60 minutes. With footForma integrated, it takes 40 to 45 minutes total, with much better results and significantly less hands-on time... So, I’ve been really happy with it,” said Chase Bradshaw

For Certified Orthopedics, this shift wasn’t about theory or projections, it was about real-world validation. Their technicians now deliver high-quality, standardized outcomes every time, without sacrificing speed.  

While these gains were significant for Certified Orthopedics, the implications go far beyond one clinic.  

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What this means for other practices  

What Certified Orthopedics proved is that these challenges aren’t just roadblocks, they’re opportunities to adopt smarter tools and build a stronger, future-proof lab. By adopting footForma, clinics and labs of any size, can overcome the same inefficiencies that have long held them back

• For orthotists: Greater efficiency means less time spent on modifications and more time for patient care.  

• For fabrication managers: It translates to smoother operations and room to scale.  

• For referral partners: Confidence in consistent outcomes strengthens trust and the clinic’s reputation.

Beyond day-to-day improvements, adopting footForma positions clinics, central fabricators, and manufacturers at the forefront of innovation in O&P.

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Conclusion

The challenges of manual workflows and generic digital tools don’t have to hold you back. Certified Orthopedics has already proven what’s possible: faster modifications, consistent results across the team, and a stronger position as an innovative, tech-advanced leader in orthotics.  

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Now it’s your turn.

Take the next step toward efficiency, repeatability, and growth in your own practice.  

Download footForma today and future-proof your workflows with technology built for orthotics.