3D Foot Scanning and Orthotics Platform

Industry: Healthcare, podiatry and custom orthotics manufacturing
Organisation: Australian orthotics technology provider
Solution type: Desktop app, web portals, hardware integration and billing
Core technology: .NET, Angular, SQL Server, Azure, 3D scanner integration, Xero, AutoCAD
Engagement: Design, development, cloud architecture and testing

Headline resultOrthotics delivered in about a week instead of waiting on posted plaster casts

Overview

Podiatry clinics traditionally take plaster casts of a patient’s feet and post them to a lab to make custom orthotics. We built a healthcare software platform that replaces this with 3D foot scanning, digital prescriptions and electronic delivery to the lab, along with order tracking and automated billing.

The Business Problem

Plaster casting is slow, messy and inconsistent. Casts must be couriered to the lab before manufacturing can start, adding cost, delays and admin. Once a cast left the clinic, practitioners had little visibility of where the order was.

Inconsistent castingManual casting with inconsistent results
Postage delaysPostage costs and delays before production
No order trackingNo order tracking for clinics
Manual billingManual billing and reconciliation

Our Solution

Clinicians scan the patient’s foot with a connected 3D scanner, complete a digital prescription covering materials, adjustments and notes, then submit it. The scan, prescription and metadata travel securely to the lab through a cloud portal.

The platform includes a desktop scanning application, a clinician portal, a lab portal and an admin and billing portal. Labs import scans into AutoCAD for 3D printing and update order status, while monthly invoices are generated from scan usage and reconciled in Xero. The architecture follows MACH principles with core workflows running as microservices on Azure.

Clinician scans the foot
Digital prescription completed
Scan sent securely to the lab
Lab imports into AutoCAD
Order tracked through to billing

3D foot scanning and orthotics ordering platform

Key Features

3D foot scanner hardware integration
Digital prescriptions with materials and adjustments
End to end order tracking for clinics and labs
High resolution STL export for CAD and manufacturing
Import and export of STL and other mesh formats
AutoCAD workflow integration for 3D printing
Automatic invoice generation from completed orders
Monthly billing by clinic usage with Xero reconciliation
Patient history and prescription records

Outcomes

Significantly faster turnaround, with orthotics typically delivered within about a week
Lower costs by removing plaster moulds and postage
More consistent, precise manufacturing from digital scans
Less waste and shipping, reducing environmental impact
Full order visibility for clinics
Mobile scanning using LiDAR on supported phones and tablets, removing the need for dedicated hardware
AI assisted scan analysis
Support for other medical scanning use cases and health system integrations

Technology Stack

Frontend4 technologies

Angular

HTML

CSS

JavaScript

Backend5 technologies

.NET

REST APIs

Entity Framework

Microservices

Database1 technology

SQL Server

Cloud and DevOps4 technologies

Azure Web Apps

Azure API Management

Azure Blob Storage

Azure DevOps

Integrations3 technologies

3D Foot Scanner

Xero

AutoCAD

Who This Solution Suits

This approach suits podiatry groups, orthotics and prosthetics labs, medical device companies and any healthcare business that wants to connect scanning hardware with digital ordering, manufacturing and billing.