How to make a FreeForma order with the Forma desktop app.

The Forma Desktop App enables orthotists and clinicians to design, customize, and export high-quality 3D orthotic devices with precision. In this guide, we’ll walk you through the full process, from scan preparation to final export.

To begin, open the Forma desktop application. The first step is to select a folder where your project files will be saved. Once the folder is chosen, you’ll be prompted to enter a project name, to help keep your cases organized.

Importing the scan

Next, you’ll be asked to upload a scan of the patient’s limb. Both .OBJ and .STL file formats are supported. After importing the scan, choose the appropriate product type, for example the H2 orthosis, and confirm by clicking Save.

You will then be prompted to provide some basic scan information:

• Select whether it is a left or right limb.
• Indicate if this is the limb to be immobilized. If not, the software will automatically mirror the scan.
• Confirm the unit of measurement (e.g. millimeters).
• Enter the thumb circumference, which is used later to size the thumb opening accurately. 

Correcting and preparing the scan

Click on Start Correction to enter the scan cleanup process.

You’ll first define which part of the scan you want to keep by cropping it. Use the cropping tools to trim the scan and orient the cutting plane as needed. You’ll be asked to place landmarks to guide this step. The software will display the length from the wrist to the cutting plane to help you verify positioning.

At this stage, you can choose between two correction modes:

• Basic mode, which lets you correct only the wrist
• Advanced mode, which includes multiple joints

Using the Basic mode, you can then adjust the wrist position by modifying its abduction/adduction and flexion/extension. After validation, you’ll move to the thumb correction.

Here, you’ll place additional landmarks. The thumb circumference you entered earlier is used to automatically create a rounded cylinder around the thumb, ensuring a proper opening. While you can adjust the circumference, it is generally best to keep it as is to maintain fit accuracy.

If needed, you can also sculpt the model to relieve potential pressure points. For instance, you might add 3 mm of volume over the styloid to improve comfort. Once all adjustments are made, validate your changes and save.

Designing the 3D model

Now it’s time to open the scan in the FreeForma design environment. This tool gives you complete freedom to build your orthotic model.

You can begin by using the brush tool to draw custom trimlines. If there are any gaps or voids in the mesh, use the bucket tool to fill them. To refine your design, you can use the erase tool to smooth areas or create ventilation holes. Mistakes are easy to fix thanks to the undo option, and the software includes automatic smoothing when you proceed to the next step.

In this step, you can fine-tune the mechanical properties of the orthosis.

• Set the global thickness (e.g. 1.5 mm by default, but can be adapted to the material you will print the device in)
• Add local thickness in areas that need extra reinforcement (e.g. 4 mm). This feature is an added value for the Freeforma workflow, as it allows to apply local thicknesses.
• Modify the global offset, which defines the space between the limb and the device
• Adjust boundary thickness, apply flare to edges, or add a margin around the thumb

Each setting is optional, but together they allow for highly personalized designs.

After shaping the model, you can place closing systems. FreeForma supports several options, including:

• Rivet holes
• Pins
• External belt loops
• Slotted/internal belt loops

You can mix and match closures depending on the use case. Position them manually and adjust their length, width, thickness, and clearance to fit your needs. All closure elements remain editable even after placement.

To finalize the design, you have the option to engrave a serial number or label directly onto the model. Enter your desired text (e.g. “Test_H2”), and select where to engrave it — typically on the inside of the device.

If you return to edit closure systems afterward, the app will prompt you to reapply the engraving.

Once everything is validated, proceed to the Export step. The software will generate two files:

• The cleaned scan
• The 3D printable model

Both will be saved automatically in the folder you selected at the beginning of the process.

Your FreeForma H2 model is now complete and ready to be submitted to Spentys or sent for manufacturing.

Watch the full video tutorial

For a visual walkthrough of the entire process, you can watch the tutorial here:
Watch the FreeForma Desktop Demo