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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