The AutoForma design tool, available within the Forma Desktop App, allows you to generate consistent, high-quality orthotic devices with minimal manual input. This automated process ensures reproducible designs and efficient workflows.
Setting up your project
To begin, launch the Forma Desktop App. You’ll first be asked to select a folder where your files will be saved. Once that’s done, enter a project name to organize your work clearly.
Importing the scan and product selection
Once your project is created, import your 3D scan. The software supports both .STL and .OBJ formats.
Next, select the product type. In this case, choose the A1 orthosis.
Before proceeding, provide some basic scan information:
- Indicate whether the scan is from the left or right limb
- Confirm whether the scanned limb is the one to be immobilized. If not, the app will automatically mirror the scan
- Set the unit of measurement (e.g., millimeters)
Scan correction and cleanup
Click Start Correction to begin refining the scan.
Now proceed to clean up the scan. Select the relevant region you want to keep, and use the cropping tool to trim the model. You’ll be prompted to place landmarks, which guide the cropping plane and indicate anatomical references. You can also tilt or rotate the cropping plane for better alignment.
Once cropped, choose between:
- Basic mode, where only the wrist can be corrected
- Advanced mode, which lets you correct all joints and articulations
In advanced mode, use the control points (bubbles) to adjust:
- Abduction/Adduction
- Flexion/Extension
- Thumb IP joint
- MCP joints of the fingers
Sculpting for pressure relief
Next, you have the option to sculpt the scan to improve comfort and avoid pressure zones.
You can:
- Add volume in areas like the styloid or ulna (e.g., +2.5 mm)
- Remove material from sensitive regions such as the thumb
Adjust the brush size and sculpting limits as needed.
Creating the 3D model with AutoForma
Now that your scan is cleaned and sculpted, you can start the automated design process in AutoForma. The landmarks from the correction step are retained, so there’s no need to reapply them.
The app will load a standard template onto the scan, which you can fully customize.
Start by adjusting the length of the orthosis. If needed, shorten or extend it to fit the clinical goal.
Next, customize the hole pattern (alveolar structure):
- Modify the boundary width (distance between the trimline and first row of holes)
- Toggle the hole pattern on or off to create either a ventilated or solid design
- Adjust the width and density of the pattern by clicking directly on the alveoli
Finally, adjust the trimlines. Click on the perimeter and reposition the control points to shape the model exactly how you want it.
Once satisfied, click Validate. The software will automatically smooth the model in the next step.
Modifying structural parameters
After smoothing, you can define global and local design specifications:
- Set the global thickness (default is 3 mm)
- Adjust the global offset to control the space between the limb and the orthosis (e.g., for padding or foam)
- Add flare to the edges for easier donning/doffing
- Refine the boundary thickness to make the edges thinner or thicker than the rest of the model
Click Next to proceed.
Configuring closing systems
By default, AutoForma adds six external beltloops to the model.
You can:
- Click on any belt loop to customize its length, thickness, width, and clearance
- Use “Select All” to update all belt loops simultaneously
- Remove external loops if desired and replace them with:
- Rivet holes
- Slotted/internal beltloops
- Pins
Mix and match closures to best suit your fabrication process or patient preferences.
Adding engraving
In the final customization step, you can engrave a serial number or label onto the model.
For example, enter “Test_A1” and select the desired location — inside or outside the device.
Validate when done.
Finalizing and exporting the model
Once you validate the model, click Save and Exit, then proceed to Export.
Both the cleaned scan and the final 3D model (print file) will be saved in the folder you selected at the beginning of the project.
Your AutoForma A1 orthosis is now ready for manufacturing or submission to Spentys.
Want to see it in action?