Manufacturing Capabilities

Health Sphere network labs combine advanced digital workflows, precision fabrication, and experienced technicians to deliver consistent custom orthotic manufacturing across North America.

Digital Prescription & Scanning

Our facilities support modern digital intake workflows that reduce turnaround time and improve prescription accuracy.

3D foot scanning for fast, accurate digital impressions
Compatible with leading mobile scanning platforms
Secure upload through provider portals for design and production
Reduced reliance on foam boxes, plaster, and fiberglass molds

CAD/CAM Design & Production

Every device is designed and manufactured using computer-aided design and CNC-controlled production for repeatable quality.

Digital orthotic modeling and prescription-driven modifications
CNC milling and precision shell fabrication
Multi-density materials and configurable shell thickness
Volume production with in-process quality checkpoints

Materials & Customization

Clinicians can specify materials and modifications to match patient needs, activity level, and footwear requirements.

Top Covers

Protective and comfort-oriented cover materials selected for durability, moisture management, and patient comfort.

Shell Options

Carbon composite and polypropylene shells in multiple thicknesses for functional control, flexibility, or low-profile fit.

Additions & Modifications

Metatarsal pads, heel lifts, and specialized posting
Arch fills and cushioning layers for sport and accommodative designs
Shell adjustments for fit, comfort, and performance over time
Posting modifications for precise alignment and control

Quality & Consistency

Standardized processes across our network help ensure every facility delivers devices that meet the same clinical and manufacturing expectations.

Premium material selection and craftsmanship
Documented inspection at key production stages
Dedicated clinical and customer support throughout the order lifecycle
Continuous improvement across all network locations