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From Plaster to Pixels:
Revisiting the Sustainability of Rapid Manufacturing in Orthotics & Prosthetics (2011–2026)
Author
Jose L. Gonzales Jr., CO, LO
Orthotist • Researcher • Founder, ForgeAxis
Summary
This paper revisits an original research proposal written in 2011 that examined whether rapid manufacturing technologies were sustainable within Orthotics and Prosthetics.
With fifteen years of technological advancement and clinical integration now available for analysis, this updated white paper evaluates how digital manufacturing has evolved within the profession.
The findings suggest that while rapid manufacturing did not replace traditional fabrication methods, it has become an important component of a broader digital workflow that has transformed design, documentation, and communication within O&P.
Key Takeaways
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Rapid manufacturing did not replace traditional fabrication methods
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Digital workflows have significantly improved design and documentation
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3D scanning and CAD have become widely adopted in clinical practice
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Additive manufacturing is most effective within a broader workflow
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Traditional fabrication techniques remain essential
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Successful adoption of digital tools depends on workflow integration, not equipment
Who It’s For
This paper is intended for professionals working within Orthotics and Prosthetics, including:
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Orthotists and Prosthetists
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Technicians and Fabrication Specialists
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Clinical Managers and Practice Owners
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Students and Residents in O&P programs
It is particularly relevant for those evaluating or implementing digital manufacturing workflows within clinical practice.
Why It Matters
Fifteen years after the original proposal, this review examines which predictions became reality and what lessons digital transformation offers the profession today.
Download / View PDF
Open-access resource. No registration required.
Updated Review: May 2026
Original Research Proposal: 2011
Full white paper (PDF) — 8 pages
Reading Time: ~12 minutes
Category: Research Review
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