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We talk with Maurice Johnson from Floyd Brace and Limb about what it really takes to scale digital fabrication in a multi-clinic prosthetics and orthotics business without losing quality. We get candid about software friction, printer economics, adjustable socket ethics, and why turnaround time and cash flow often matter as much as the tech.

• Floyd Brace and Limb’s growth from a one-office shop to a multi-location model
• why centralizing fabrication matters when clinicians need to stay patient-facing
• the industry’s fragmented scanning to CAD to print workflow and why it blocks repeatability
• what Floyd prints today and why definitive sockets still often stay carbon fiber or outsourced
• real-world cost targets and the volume problem with larger printers
• AirFit-style transtibial consistency as a way to reduce heavy CAD dependence
• Formlabs size limits, throughput questions, and hybrid print plus outsource strategies
• adjustable sockets as both a patient benefit and an ethical billing discussion
• material extrusion TPU flexible inners as an alternative to powder-bed fusion variability
• early thinking on 3D printed SMOs and by-measurement versus cast-and-scan workflows

Special thanks to Advanced 3D for sponsoring this episode.

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Guest Zoltan Karpati explains scan-to-fit, AI landmarking, and XR training while sharing a personal pet prosthetics story and a unified roadmap.

• replacing clear checks with real flexible interfaces for truer diagnostics
• extending second diagnostic wear to validate cushioning and relief
• controlling variables by avoiding returns to the old socket
• dialing fit with adjustable sockets and reduced manual labor
• scan-to-fit workflows with phone-based scanning and AI landmarks
• exporting to 3D printing or CNC with white-label options
• spatial reality training screens for classroom-friendly 3D design
• product roadmap for insoles, AFOs, and order management system
• personal story powering pet prosthetic development

Special thanks to Advanced 3D for sponsoring this episode.

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We explore how pricing, policy, and 3D printing are reshaping orthotics and prosthetics from the UK to the Gulf and across Africa. Hugh Sheridan shares hard truths about aid that bypasses clinics and a road map for sustainable, locally led care.

• roots in shoe materials evolving into O&P supply chains
• UK reimbursement pressures and the pivot to prefabs and 3D printing
• UAE as a hub versus Saudi growth and privatisation
• pediatric disability needs and cultural barriers to access
• why direct aid can starve local clinics of patients and revenue
• franchise-style partnerships as a sustainable aid model
• China and Turkey’s rising role in components and materials
• open materials, SLS/MJF economics, and avoiding lock-in
• central fabrication versus in-clinic making and clinician psychology
• direct scanning, hybrid workflows, and protecting clinical value

Special thanks to Advanced 3D for sponsoring this episode.

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