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Philip Carter's drone fully assembled When Philip started building aircraft as a teenager, he wasn’t just exploring how things fly—he was questioning how they should . Years later, he’s become a specialist in a complex area of drone design: ducted, counter-rotating propulsion systems that emphasize safety, reduced noise, and control. “My drones aren’t flying cameras,” Philip says. “They’re platforms for testing new propulsion concepts.” With experience contributing to open-source tools like MIT’s Xrotor and the FTC suite, Philip builds drones from the ground up. His goal is to develop compact, quiet UAVs that are safer to operate near people—and more efficient than traditional open-rotor designs.Achieving that means working within tight design constraints. “We’re running at 14,000 RPM with 0.7 mm tolerances,” he explains. “You can’t prototype that with off-the-shelf parts. The material and accuracy have to be reliable.” That’s where Tempus 3D came in. Very tight tolerances between the blades and the duct Using HP’s Multi Jet Fusion 5200 system, Tempus helped Philip prototype complex components—fan ducts, housings, and control structures—with the precision and durability needed for high-performance testing. “Tempus made it possible to move quickly without compromising on quality,” he says. “I’m not building for show—I’m building to solve real engineering problems. That means fast iteration, aggressive testing, and confidence in the parts I’m using.” Philip also designed a custom 2-axis gimbal rig and thrust bench to measure performance in real-world conditions, allowing him to refine each iteration without risking a full flight test. His advice to others working in UAV development? Skip the templates. The custom test gimbal “There are enough cookie-cutter quadcopters out there. If you’re going to build something, make it count. Innovate.” At Tempus 3D, we’re proud to support that kind of work—engineering that moves the field forward, one well-built part at a time.

Introduction This case study walks through the step-by-step development of a generatively designed drone frame, with a focus on cutting down weight and improving structural performance. Using the high-precision HP Multi Jet Fusion 5200 printer, we refined our first prototype to strike a better balance between weight, strength, and airflow. Background The original frame was built in Autodesk Fusion 360 using its Generative Design tool, with the goal of making the chassis as strong as possible while taking advantage of the geometric flexibility that Multi Jet Fusion (MJF) 3D printing offers. While the first design turned out to be solid and stiff, it missed the mark when it came to weight savings. So, for version two, the goal shifted to dialing in meaningful weight reduction while still keeping the frame strong enough for reliable flight. Key Objectives Reduce overall frame weight without compromising strength. Distribute loads more effectively to keep flex behaviour predictable. Clean up the aerodynamics by cutting out material that messes with airflow. Analysis of Version 1.0 What Worked: Dimensional Accuracy:  All the mounting points and holes were exactly where they needed to be. Battery Holder Design:  Fit in seamlessly without causing any weird bending forces. Structural Reinforcement:  The spars connecting the arms to the battery holder helped a lot with crash protection. Aesthetic Appeal:  The frame looked good and had a clean, purposeful design. What Didn't: Too Heavy:  Despite using generative design, the frame ended up heavier than we wanted. Overbuilt Sections:  Some areas were reinforced more than needed, adding bulk without much benefit. Rear Arm Flexing:  In flight, the rear arms twisted a bit, messing with motor alignment and reducing efficiency. Blocked Airflow:  Some front structural parts were in the way of the propellers, hurting performance. Root Cause Analysis Here’s what led to the issues: Generative Design Settings:  Using the "Minimize Mass" setting led to more material being added to fight flex, which backfired on the weight-saving goal. Estimated Forces:  We based simulations on rough guesses rather than actual flight data, so we ended up over-reinforcing the frame. Post-Processing Edits:  Some manual tweaks in Blender introduced weak spots we didn’t intend. Revised Approach for Version 2.0 To fix those issues, we made a few key changes: Updated Design Objective:  Switched to "Maximize Stiffness with a Target Weight" to better balance strength and weight. Set a Clear Weight Goal:  Targeted a final weight of 12 grams, based on comparisons with other FDM-printed frames and what we learned from v1.0. Better Force Estimates:  We used more accurate force estimates that better matched real flight conditions. Implementation With those updates, we created a new generative design in Fusion 360. Here’s what came out of it: Hit the Weight Target:  The frame now weighs 12 grams—right on target. Rear Arm Improvements:  Flexing is now predictable and controlled, which helps keep flights stable. Better Aerodynamics:  Front structures were trimmed down, improving airflow around the propellers. Print-Ready Design:  The frame was optimized for Multi Jet Fusion printing, making use of the process’s ability to handle intricate details. Results and Key Findings Nailed the Weight:  The final weight came in exactly at 12 grams. Good Strength-to-Weight Ratio:  The frame kept its strength while shedding unnecessary material. Improved Flight Performance:  Controlled arm flexing led to better motor alignment and more efficient thrust. Clean Airflow:  By reducing material in the wrong spots, we boosted aerodynamic performance. Conclusion and What’s Next This project shows how refining a design through iterations—and combining that with powerful tools like generative design and Multi Jet Fusion 3D printing—can result in a highly efficient, lightweight drone frame. For the next version, we plan to use real-world flight data to make our load simulations even more accurate and explore ways to make the frame more aerodynamic and crash-resistant.

How 3D Printing is Taking Aerospace to New Heights The aerospace industry has always been a playground for cutting-edge innovation,and 3D printing, also known as additive manufacturing, is one of the most exciting technologies transforming this field. From lighter aircraft components to faster production cycles, the impacts of 3D printing are nothing short of revolutionary. Let’s explore how this technology is reshaping the skies 1. Lightweight 3D Printed Aerospace Parts One of the most significant advantages of 3D printing in aerospace is its ability to produce lightweight yet strong components. Traditional manufacturing methods often result in heavier parts due to design limitations. However, 3D printing allows engineers to create intricate geometries that minimize weight without compromising strength. This "lightweighting" improves fuel efficiency, extends aircraft range, and reduces carbon emissions—key priorities for modern aviation[1][2][4]. 2. Faster Aerospace Prototyping and Production Gone are the days when prototyping took months. With 3D printing, aerospace companies can design and produce prototypes in a matter of hours or days. This rapid iteration accelerates innovation and shortens development timelines for new aircraft or spacecraft designs. It also enables faster testing and refinement, ensuring safer and more efficient final products[1][4][6]. 3. Cost Savings from 3D Printed Aerospace Components 3D printing eliminates the need for expensive molds and tooling used in traditional manufacturing. It also reduces material waste by using only what’s necessary to build each component. Additionally, on- demand production means fewer spare parts need to be stockpiled, cutting storage costs and streamlining supply chains[4][7][9]. 4. Enhanced Aircraft Maintenance and Repair Aircraft maintenance often involves long lead times for replacement parts. With 3D printing, airlines can produce custom spare parts directly at maintenance hubs, reducing downtime and keeping planes in the air longer. This capability is particularly useful for older aircraft models where spare parts may no longer be readily available[7][9]. 5. Driving Aerospace Design Innovation with 3D printing Perhaps the most exciting aspect of 3D printing is its ability to unlock new design possibilities. Engineers can create complex shapes and structures that were previously impossible or too costly to manufacture traditionally. This opens doors to improved aerodynamics, better heat resistance, and entirely new functionalities in aerospace components[2][6][8]. 6. Sustainability Benefits of Additive Manufacturing in Aerosapce In an industry under pressure to reduce its environmental impact, 3D printing offers significant sustainability advantages. By minimizing material waste and enabling lighter designs, it contributes to lower energy consumption during both manufacturing and operation. Some studies suggest reductions in CO2 emissions of up to 75% when additive manufacturing is used strategically[4][8] The Sky’s the Limit As 3D printing technology continues to evolve, its role in aerospace will only grow more prominent. From improving efficiency and reducing costs to enabling groundbreaking designs, additive manufacturing is helping the aerospace industry reach new heights—literally and figuratively. The future? Safer, greener, and more innovative aircraft that push the boundaries of what’s possible So next time you board a plane, remember: there’s a good chance that some of its parts were born from a 3D printer! Sources [1] HOW 3D PRINTING IS CHANGING THE AEROSPACE INDUSTRY Add a little bit of body text [2] The Impact of 3D Printing in the Aerospace Industry Add a little bit of body text [3] Revolutionizing the Aerospace Industry: 3D Printing Solutions for ... Add a little bit of body text [4] The Future of 3D Printing in Aerospace Manufacturing Add a little bit of body text [5] The Current State of the Art and Advancements, Challenges, and ... Add a little bit of body text [6] Advancements in 3D Printing are Revolutionizing the Aerospace ... Add a little bit of body text [7] 3D Printing for Aerospace: introduction, advantages and applications Add a little bit of body text [8] Additive manufacturing in aeronautics: the future of aircraft Add a little bit of body text [9] 3D Printing in Aerospace Industry – Raise3D Add a little bit of body text

The Benefits of Keeping Manufacturing Local: A Client Spotlight on Rainman   In product development, being able to work closely with a manufacturer can make a huge difference. Charlie O-Shea, founder of Rainman, has seen this firsthand. By partnering with Tempus 3D, a Canadian additive manufacturing company, he’s been able to take a more hands-on approach, ensuring his products are made efficiently and with minimal error.  "The benefits and purpose of working with Tempus 3D, a local manufacturing company, is the ability that you can work closely, with a hands-on approach.... and make changes if needed. No second guessing through emails and less time wasted with mailing and deliveries. This can end up being a substantial savings." – Charlie O-Shea, Rainman  Why Work with a Canadian Manufacturer?  Faster Turnaround & Cost Savings  Working with an overseas manufacturer often means long lead times, unexpected shipping costs, and delays. Keeping production local eliminates a lot of that hassle. As Charlie points out, fewer emails, reduced shipping time, and the ability to make changes in person add up to serious time and cost savings.  Hands-On Collaboration & Quality Control   Having direct access to a manufacturing partner allows for quicker decision-making and fewer mistakes. Rather than going back and forth over emails, businesses can meet in person, see the production process firsthand, and make necessary adjustments right away. That kind of direct involvement ensures a higher level of quality and precision.  Supporting Local Innovation & Sustainability   Choosing a Canadian manufacturer doesn’t just benefit individual businesses—it supports the local economy and helps drive innovation at home. It also reduces the environmental impact of international shipping, making the entire process more sustainable.  How Rainman Benefits from Local Manufacturing   By working with Tempus 3D, Charlie has been able to streamline production, minimize errors, and get products to market faster. It’s a great example of how local partnerships can make manufacturing more efficient and reliable, and much less stressful!  For companies looking to improve their production process, working with a Canadian digital manufacturer like Tempus 3D (link) offers real advantages—clear communication, lower costs, and a stronger connection between design and production. Be sure to check Charlie's Instagram!: https://www.instagram.com/rainman_raincovers/?hl=en

At Tempus 3D, we love working with Canadian businesses to turn ideas into reality. Every day, we see the impact that high-quality 3D printing in Canada has on companies of all sizes—helping them cut costs, speed up production, and bring innovative products to market. From small startups to established industries, we’re here to make digital manufacturing in Canada more accessible, and we take pride in being part of their success stories.  Making the Leap from Prototyping to Production  We’ve talked to countless businesses that struggle with the jump from prototype to full production. Traditional manufacturing methods can be expensive, slow, and rigid. That’s where we come in. Tempus 3D provides industrial 3D printing services in Canada that help businesses move smoothly from concept to final product. Using HP Multi Jet Fusion 3D printing, we create durable, high-performance parts that are ready for real-world use—whether in aerospace, medical, consumer goods, or beyond.  Helping Canadian Companies Push the Boundaries  One of our favourite things is seeing how diverse Canadian businesses use 3D printing technology in their own unique ways. We’ve worked with startups designing wearable medical devices, agricultural businesses creating custom equipment parts, and drone manufacturers refining lightweight, high-strength components.  Take, for example, the orthotics industry. By working with Tempus 3D, Canadian orthotics providers can produce custom, patient-specific 3D-printed foot orthotics with unmatched precision and speed. Instead of waiting weeks for traditionally manufactured orthotics, patients get the perfect fit in a fraction of the time. It’s partnerships like these that make a real difference in people’s lives, and we’re honoured to be part of that process.  Helping Small and Medium-Sized Businesses Grow  We understand that Canadian small businesses often face challenges when it comes to manufacturing. High setup costs, minimum order requirements, and long production cycles can make it tough to compete. Tempus 3D helps by offering low-to-mid volume production runs without the need for expensive molds. This allows entrepreneurs and product developers to iterate quickly, manufacture on demand, and avoid the risks of overproduction.  Making Sustainability a Priority  We know that more and more Canadian companies are looking for ways to reduce waste and build sustainability into their operations. That’s why we love the efficiency of 3D printing for sustainable manufacturing—it uses only the material needed, cuts down on transportation emissions by keeping production local, and allows for lightweight part designs that improve overall efficiency. It’s a win for both businesses and the planet.  More Than a Service Provider—A Manufacturing Partner  At Tempus 3D, we don’t just print parts; we guide our clients through the 3D printing process to ensure they get the best possible results. We help businesses navigate material selection, part optimization, and production planning so they can make the most of industrial 3D printing. Whether it’s an aerospace company refining high-performance components or a product developer bringing their latest creation to life, we’re here to support Canadian businesses with reliable, high-volume additive manufacturing.  Let’s Build Something Great Togethe r  If you have an idea or a 3D printing manufacturing challenge, we’d love to hear about it! Whether you’re a small business, a startup, or a large enterprise, Tempus 3D is here to help bring your vision to life. Get in touch with us today to learn more about industrial 3D printing in Canada and let’s create something amazing together.

At Tempus 3D, we’re not just about cutting-edge 3D printing—we’re all about that genuine Canadian spirit. Proudly Canadian-owned and operated, our roots run deep in the heart of beautiful British Columbia, where the great outdoors meets modern manufacturing.  We’re a team that’s passionate about transforming ideas into reality. Whether it’s for aerospace, automotive, healthcare, or any innovative industry, we blend top-notch precision with a friendly, outstanding service. We love being able to work with other great Canadian companies, government organizations, as well as students embarking on their first forays into digital manufacturing. Staying local means fast turnarounds, exceptional quality, and that unmistakable Canadian charm that makes our projects uniquely awesome. So, if you’re ready to turn your ideas into 3D printed reality with a partner who values creativity, reliability, and maybe a large double-double, Tempus 3D is here for you.  Let’s partner on a journey and get your products Made In Canada — where innovation meets the True North!

By: Jonathan Guercio Introduction:   The holiday season is a fantastic time for getting creative! This year I wanted to make something fun while also showcasing the amazing power and capabilities of our HP Multi-Jet Fusion 3D printer. This printer can produce extremely complex geometries without the need for supports, capture fine details, and manufacture parts from durable PA-12 Nylon material. It looks like I have a fun challenge ahead—and I hope to make this a Tempus 3D tradition in the future!  The Inspiration:   Sometimes the most striking effects come from the simplest designs! Of course, that’s easier said than done. One trick I’ve learned when designing is that it’s always better to start simple and then add complexity layer by layer (pun intended). This approach helps keep the project scope manageable and prevents over-design. So, how simple should we start? The Tree Bauble—a simple, recognizable, traditional shape!  MJF Benefits:   The key objective for our holiday project was to take full advantage of our HP MJF printer’s capabilities. A simple ball would have been no challenge at all! To start, let’s identify the key strengths of Multi-Jet Fusion printing.  No Supports Needed   More common forms of 3D printing—such as FDM or resin-based printing—usually require supports. Since additive manufacturing is performed layer by layer and cannot print in empty space, supports act like scaffolding to hold overhangs in place until the print is completed. With Multi-Jet Fusion printers, however, a full layer of powder is deposited on every layer. The machine then fuses only what it needs, leaving the unfused powder in place to act as a support. After printing, the unfused powder is removed and reused! This process enables the creation of intricate, tight geometries that would otherwise be impossible—and as a bonus, there are no support artifacts to clean up.  Strength   Our in-house HP PA-12 Nylon is incredibly robust. As a key differentiator, MJF printing delivers consistently strong parts along all axes. While other 3D printing methods may suffer from weak inter-layer adhesion that can lead to breakage, the uniform strength of MJF-printed parts opens up surprising possibilities—such as showcasing uncommonly thin features.  Dimensional Accuracy and Detail   MJF printing offers exceptional dimensional accuracy combined with a high level of detail. It truly stands at the forefront when it comes to merging strength with fine detail in on-spec real working parts.  Adding Complexity Doesn’t Add Cost   While increased complexity can sometimes make printing and post-processing more challenging, it generally doesn’t matter with 3D printing. This technology is renowned for creating forms that other manufacturing methods simply cannot, and when combined with the no-supports-needed advantage mentioned above, the design possibilities are virtually limitless!  Adding Complexity:   Given the strengths of MJF, let’s develop a plan to implement them! My idea was to start with a simple sphere and place the Tempus 3D logo right in the middle—a feat difficult to achieve with any other manufacturing technique. I began with a 2D sketch of the basic shape. Since the design is a hollow sphere, I decided that using a 2D profile with the revolve tool would be the easiest way to achieve the desired shape. In this case, I decided to put almost all the features into a single sketch, you’ll see why later.  I opted for a 3-inch diameter with a slim 2.75mm thickness for the outer profile. You can also see the logo plaque here. Note that I didn’t constrain the plaque size because I wanted the flexibility to adjust it later in the modelling process. After adding a simple top hanger, it was time for the first 3D operation!   The first operation was straightforward: creating the outer hollow sphere. I used the revolve tool by selecting half of the outer profile and rotating it about the central axis.  Now that we have our sphere, it’s time to get creative! I started by creating a new sketch a few millimeters from the surface using an offset plane. This sketch defines the intricate “ribs” of the bauble. But rather than drawing the ribs directly, I sketched the areas to be removed, leaving the ribs behind.  As you can see, the blue lines indicate that the sketch is unconstrained. This was intentional, as an unconstrained sketch allowed me to adjust the lines until I achieved the desired look. I continued playing with these lines throughout the process, making it easy to perfect the design.  Once I was close to the desired shape, I used the extrude tool to cut the design out of the sphere.  Now that I had a single cut, how could I transform it into the intricate final shape? This is where the magic happens—the circular pattern tool! I selected “Feature” as the Object Type, which allowed me to pattern the extruded cut (highlighted at the bottom of the screen). Next, I chose the axis around which to pattern the feature and experimented with the number of repetitions, eventually settling on 20.  The result is quite dramatic, despite the simplicity of the procedure!  The Center:   Now that we have our bauble, it’s time to add the logo plate and hanger loop. Fortunately, the necessary sketch was already prepared. Let’s start with the logo plate. I used a symmetrical extrude to ensure that the plate remained centered on the bauble. To add our logo, I imported a vector outline of our Tempus 3D logo, created a new sketch on the plate, and positioned it appropriately before performing a simple extrude. In this case, I extruded 1mm to make it easier to see through the ribs.  Next is the hanger loop—a simple square with carefully considered dimensions. Again, I used the symmetrical extrusion tool to ensure it was perfectly centered.  Finishing Touches: Fillets   Why dedicate a separate step to adding fillets? There’s a common saying: “The fillet tool is the most expensive tool in CAD.” This isn’t because it’s difficult to use, but because each additional fillet can increase production costs—whether through extra CNC machining time or by complicating injection molds. Fortunately, this ties directly into the fourth benefit of MJF mentioned above. In our case, adding fillets has no impact on the printability of the bauble. So, feel free to fillet away!  I hope you enjoyed this write-up, and that some of you are inspired to try CAD if you haven’t already. This was a fun little in-house project!

Now we are getting to the potatoes! When it comes to creating custom orthotics, precision and efficiency are key. Traditionally, CNC machining has been the go-to way for producing these devices. However, the rise of 3D printing in the advanced manufacturing era is transforming how we approach this field. Both technologies have their merits, but when it comes to modern orthotics, 3D printing offers key advantages.  The Traditional CNC Machining Approach  CNC machining is a subtractive form of manufacturing. Itinvolves cutting away material from a solid block to create a final product. For orthotics, this process typically starts with a block of foam or plastic, which is milled into the desired shape. This method is known for its:  Precision:  CNC machines can produce highly accurate orthotics tailored to a patient's needs.  Material Variation:  It is easy to change out material type based on client needs.  However, CNC machining also comes with notable limitations:  Material Waste:  Significant amounts of material are removed during machining, resulting in higher waste.  Complexity Constraints:  Designing intricate, organic shapes can be challenging and time-consuming.  Time-Intensive Setup:  Each custom piece requires careful programming and calibration, adding to lead times.  The Game-Changer: 3D Printing for Orthotics  3D printing takes a completely different approach by building orthotics layer by layer from a digital design. This additive manufacturing method brings several unique advantages:  Design Freedom:  3D printing enables the creation of complex geometries, such as lattice structures, that are impossible to achieve with CNC machining. These designs can enhance comfort and functionality by optimizing weight distribution and even airflow.  Material Efficiency:  Since material is only deposited where needed, waste is dramatically reduced. This not only lowers costs but also supports sustainability.  Speed and Scalability:  Once the digital design is finalized, multiple orthotics can be printed simultaneously, significantly speeding up production. In a machine like ours at Tempus 3D, we can print nearly 100  pairs in a single print!  Enhancing Patient Outcomes  For patients, the benefits of 3D-printed orthotics are transformative. Lighter, more breathable designs enhance comfort during wear, while precise customizations ensure better alignment and support. Additionally, the speed of production means patients spend less time waiting for their orthotics to be ready.  Choosing the Right Technology  While CNC machining has been a reliable method for decades, 3D printing is quickly becoming the preferred choice for producing orthotics. It offers unparalleled flexibility, efficiency, and innovation that align with the evolving needs of both patients and practitioners.  As the orthotics industry continues to embrace 3D printing, we're excited to see how this technology will further improve patient care and redefine the boundaries of custom manufacturing!

Introduction:  After an orthotic is 3D printed, it undergoes a series of post-processing steps to enhance its appearance, durability, and functionality. Depending on the final assembly, these finishing touches could make a significant difference in patient satisfaction and long-term wear. This week in our campaign we’ll explore the most common post-processing techniques used for 3D printed orthotics! Dyeing:  Dyeing is a common technique used to color the orthotic. Many orthotics start out as grey or white, but dyeing allows clinicians to offer custom colors, which can enhance aesthetics and patient preference.  Benefits:  Adds a more complete look, can be customized to patient preference.  Drawbacks:  Requires additional time and equipment.  Vapor Smoothing:  Vapor smoothing is used to create a smoother surface finish on the orthotic. This is especially useful for materials like PA-12, which can have a slightly rough texture after printing.  Benefits:  Smooth, polished finish, a sealed easy to clean surface.  Drawbacks:  Not all materials are compatible with vapor smoothing.  Vibratory Tumbling:  Vibratory tumbling is another method for smoothing the surface of the orthotic. The orthotic is placed in a machine with small media (such as stones or ceramic) that gently polishes the surface.  Benefits:  Effective for large batches, smooths out imperfections.  Drawbacks:  Time-consuming, may not achieve the same finish as vapor smoothing.  Raw Finish:  Some orthotics are left with a raw finish straight out of the printer. While this is the fastest option, it may not provide the same level of aesthetic or comfort benefits as other post-processing methods.  Benefits:  Quick, no additional processing required. May be completely fine, if the orthotic is being covered with layers Drawbacks:  Rougher texture, may be less comfortable for patients.  Conclusion:  Post-processing is an essential part of the 3D printing workflow, ensuring that the final orthotic meets both functional and aesthetic standards. Whether through dyeing, smoothing, or leaving the orthotic in its raw state, these techniques allow clinicians to tailor the orthotic to the specific needs of the patient while enhancing the overall quality of the product.

Welcome to week 3! The advanced manufacturing era has revolutionized the orthotics industry, making it possible to produce customized, high-quality orthotics with unprecedented speed and precision. But with so many 3D printing technologies and materials available, choosing the right combination for your clinic's needs can be daunting. Let’s dive into the most common 3D printing methods and materials for orthotics, comparing their benefits and limitations to help you make informed decisions.    Top 3D Printing Technologies for Orthotics   1. Fused Deposition Modeling (FDM)   FDM is a widely accessible 3D printing method that works by extruding melted thermoplastic layer by layer.  Pros : Affordable, suitable for simpler orthotic designs, and easy to access.  Cons : Lower accuracy, rougher surface finishes, and fewer material options compared to advanced methods.  2. Selective Laser Sintering (SLS)   Using lasers to fuse powdered material, SLS creates durable and complex designs with a smooth finish.  Pros : Perfect for intricate geometries, highly durable, and provides excellent surface quality.  Cons : Higher costs and less availability in smaller clinics.  3. Multi Jet Fusion (MJF)   HP's MJF technology uses binding agents and heat to produce orthotics with exceptional speed and precision.  Pros : Outstanding accuracy, fast production, smooth finishes, ideal for complex designs, and well suited to large batches  Cons : Requires specialized equipment with a higher upfront cost.  4. Material Jetting (MJ)   This method involves jetting liquid materials that are cured layer by layer with UV light, delivering unmatched precision.  Pros : Exceptional detail, multi-material capability, and high-quality finishes.  Cons : Expensive and less commonly used for orthotics.  Choosing the Right Technology   Choosing of 3D printing technology often depends on your clinic's budget, the complexity of the orthotic design, and material requirements. For high-precision, durable orthotics, SLS and MJF   are leading options, while FDM and MJ work well for simpler or more specialized needs.    Exploring Material Options for 3D Printed Orthotics   The choice of material directly impacts the strength, flexibility, and comfort of orthotics. Here are the most popular materials used in 3D printing orthotics and their key characteristics. We will be focusing on the MJF materials we offer here at Tempus 3D of course! 1. PA-12 (Nylon 12)   A durable, flexible, and biocompatible material ideal for everyday o rthotics.Th is is hte most common material we do by far! Pros : High strength, impact resistance, and versatility.  Cons : May require additional finishing for smoother surfaces.  2. TPU (Thermoplastic Polyurethane)   Known for its rubber-like flexibility, TPU is perfect for orthotics requiring cushioning and shock absorption.  Pros : Excellent flexibility and comfort for patients.  Cons : Less durable and may wear faster over time.  3. PA-11 (Nylon 11)   A lightweight, bio-based material offering similar benefits to PA-12 with added flexibility.  Pros : Strong, and ideal for lightweight orthotics.  Cons : Slightly more expensive than PA-12.    Making the Right Choice for Your Patients   Selecting the right 3D printing technology and material is a balancing act between performance, cost, and patient needs. While PA-12   and TPU are versatile and widely used, materials like PA-11 cater to more specific requirements. Similarly, advanced printing methods like MJF excel in precision and durability, ensuring the highest quality outcomes for patients.  At Tempus 3D, we provide access to MJF technologies and materials, ensuring you have the right tools for any orthotic design challenge. We would love help you create orthotics that enhance patient comfort and mobility with the precision of advanced manufacturing!

By Tempus 3D with Guest Contributor: Crux Laboratory     The Future of Foot Care: Easier, Affordable, and Happier Patients with Advanced Foot Scanning   Introduction   Welcome to Week 2 of our exploration! Foot scanning technology has completely changed the way foot care professionals diagnose and treat foot-related issues. These technologies are making it easier to achieve a comfortable, custom fit for orthotics—quickly, accurately, and in a way that’s less intrusive for patients. By replacing the traditional methods with high-tech digital scans, clinics are enhancing their ability to deliver a higher level of care. In this week’s blog, we’ll explore the main types of foot scanning technologies available today, the specific benefits they offer, and why these tools are valuable for clinics aiming to provide the best for their patients.  Challenges with Traditional Foot Scanning Methods   Historically, the process of creating a custom orthotic required taking a physical impression of the foot, often using foam boxes or plaster casts. While this technique provided a baseline for creating orthotics, it was often inconsistent and prone to error. Imperfections in the cast could lead to an orthotic that didn’t fit quite right, leading to less effective treatments and the need for adjustments. Additionally, physical casting processes could be messy, time-consuming, and not always comfortable for patients.  With the introduction of digital scanning, this process has transformed. Digital scanners can capture incredibly precise 3D images of the foot in just seconds, ensuring higher accuracy, consistency, and efficiency. This not only shortens wait times but also enhances the quality of the orthotic, giving patients a product they can rely on.  Types of Foot Scanning Technology   Laser Scanners   Laser scanners employ laser beams to capture precise measurements of the foot's surface, creating a high-resolution 3D model. These scanners excel at capturing intricate details, such as subtle contours and minute variations in foot shape. This precision makes laser scanning ideal for orthotics that require complex customization, allowing for an exact fit that aligns with the unique anatomical structure of each patient’s foot. However, the level of detail and accuracy they offer comes at a cost—laser scanners are generally the most expensive type of foot scanner.  Due to their high precision, laser scanners are well-suited for clinics focused on specialized care, such as treating complex foot conditions or working with athletes who need high-performance orthotics. Additionally, the detailed data these scanners collect can be useful in research or teaching settings, where understanding the fine structure of the foot is important.  Structured Light Scanners   Structured light scanners operate by projecting a pattern of light, often in a grid or stripe, onto the foot's surface. As the light pattern deforms around the contours of the foot, cameras capture these changes, and specialized software converts them into a 3D model. Structured light scanning is known for being both fast and accurate, striking a balance that makes it ideal for high-traffic clinics where time and efficiency are important.  One of the primary advantages of structured light scanning is its speed. With these scanners, a 3D model of the foot can be captured in seconds, making them suitable for practices that need to scan multiple patients in a short period. The structured light method also tends to be less sensitive to minor patient movements, reducing the risk of distorted images. While structured light scanners may not match the ultra-fine detail of laser scanners, they still deliver a high degree of accuracy that’s more than sufficient for most clinical applications. This makes structured light scanners a versatile choice for clinics that need a dependable mix of speed, accuracy, and cost-effectiveness.  Photogrammetry (Camera-Based Scanners)   Photogrammetry scanners take a different approach, using multiple cameras positioned at different angles to capture images of the foot. These images are then processed and combined to create a 3D model. This type of scanner is generally more affordable than laser or structured light options, making it an accessible choice for clinics looking to integrate foot scanning without a significant upfront investment.  While photogrammetry scanners can still produce accurate 3D models, they may lack the high level of detail found in laser or structured light scanners. This can make them less ideal for highly specialized orthotic applications that require extreme precision. However, they are a practical choice for many general clinics and smaller practices where the emphasis is on cost-effectiveness rather than top-tier detail. Photogrammetry scanners are also portable and relatively simple to set up, which can be beneficial for clinicians who need to use the scanner in multiple locations or offer mobile scanning services.    Comparing the Scanners: Which One is Right for Your Clinic?   Each type of scanner has its own strengths, so choosing the right one depends on the specific needs of the practice:  For Maximum Precision:  If your practice requires orthotics with intricate customization, laser scanners may be the best choice due to their unparalleled detail and accuracy. This option is suitable for clinics focused on specialized care, where high-quality outcomes are a priority.  For Efficiency and Speed:  Structured light scanners offer a good mix of speed and accuracy, ideal for high-volume clinics that need a scanner capable of quickly processing patients without compromising quality. This option is suitable for general practices that aim to provide a high standard of care while keeping patient wait times minimal.  For Budget-Friendly Flexibility:  Photogrammetry scanners provide an affordable and adaptable option, great for clinics that want to introduce foot scanning without a significant financial commitment. They are best suited for practices that don’t require ultra-high precision but still want the advantages of digital scanning.    In choosing the right technology, clinics should assess their specific patient needs, workflow demands, and budget. Each scanner type has something unique to offer, and selecting the right one can help ensure that your clinic is providing the most suitable and efficient care possible.  Key Considerations When Choosing a Scanner   Accuracy:  Higher accuracy means better-fitting orthotics, which can make a real difference in comfort and effectiveness for patients. Laser scanners usually top the list in terms of precision, followed closely by structured light and then photogrammetry.  Speed:  Structured light scanners are among the fastest on the market, making them ideal for busy clinics that need to move quickly from one patient to the next. Fast scanning times mean clinicians can focus on patient care and analysis rather than waiting for scans to complete.  Cost:  While laser scanners tend to be the most expensive option, structured light and photogrammetry scanners provide more budget-friendly alternatives. It’s important for clinics to weigh these costs against the benefits they offer, taking into consideration both their budget and the type of care they want to provide.  The Benefits of Going Digital in Foot Scanning   Transitioning to digital foot scanning offers numerous advantages for both patients and clinicians. For patients, the process is faster, more comfortable, and more reliable than traditional methods, with digital scans capturing their foot’s shape and structure precisely. This leads to orthotics that are a better fit, improving both comfort and effectiveness. Additionally, digital scans allow for faster turnaround times, reducing the waiting period between diagnosis and receiving orthotic care.  For clinicians, digital scanning simplifies workflows and eliminates the need for storing physical molds, which can be cumbersome and difficult to manage. Digital files are easy to share, store, and analyze, which makes it easier for clinicians to review patient progress or make adjustments as needed. Overall, digital foot scanning supports a higher standard of care, as clinicians can offer patients a product that’s customized precisely to their needs, leading to better patient outcomes and satisfaction.  Conclusion   Whether using laser, structured light, or camera-based scanning, foot scanning technology has transformed the way clinicians approach foot care. By understanding the different options available, clinics can select the right technology to suit both their practice needs and budget. Investing in these advanced scanning tools opens the door to more efficient workflows and improved patient experiences, paving the way for a new era in personalized foot care.

By Tempus 3D with Guest Contributor:  Crux Laboratory   Over the next 9 weeks us here at Tempus 3D have partnered with Crux Laboratory in Calgary Alberta to give some insights on how a modern workflow with 3D printing has changed foot orthotics. We’re excited to collaborate with another Canadian company to show how seamless a transition to a digital workflow can be, and how 3D printing can be the best way to make an orthotic  Introduction:   Orthotic care is undergoing a transformation. While traditional methods for diagnosing and treating foot issues have long been effective, the pace and precision of modern digital technologies are setting new standards in the industry. In the coming weeks, we hear insights from clinicians who’ve made the switch to a fully digital workflow, sharing how it has enhanced both their practice and patient outcomes! Partnering with Tempus 3D,  clinicians now have a seamless end-to-end solution that not only improves efficiency but also boosts patient satisfaction.    Challenges of Traditional Orthotic Processes:   Historically, creating custom orthotics was a hands-on, labor-intensive process. Clinicians would take manual measurements, create molds, and often make repeated adjustments. Many steps were involved, with practitioners sending molds to labs and awaiting returns—a process that added time and room for error. While this approach worked, it was unfortunately far from efficient and often delayed timelines.    Why Digitize and Partner with a 3D Printing Specialist?:   Moving to a digital workflow has brought about dramatic improvements. Today’s clinicians use advanced foot scanners, which capture precise measurements and eliminate the need for physical molds. This digital data is used to make 3D models of the desired orthotic, which is then sent directly to Tempus 3D, where it’s used to produce orthotics with precision through state-of-the-art 3D printing technology. This workflow allows for quick turnaround times and a consistently high-quality fit, enhancing the comfort and effectiveness of orthotics for patients.  A Better Patient Experience:   For patients, the benefits are immediate. With a streamlined process, from the initial consultation to receiving their orthotic, they experience quicker turnarounds, fewer adjustments, and ultimately improved comfort and outcomes. Having Tempus 3D as a dedicated partner ensures that each orthotic is produced quickly and with a high degree of accuracy, is setting a new benchmark for patient care!    A Quick Comparison: Traditional vs. Digitized:   Traditional Workflow : Relies on manual molding, longer production times, and often leads to a less precise fit.  Digitized Workflow with Tempus 3D : Faster, highly accurate, and offers a degree of customization that traditional methods can’t achieve, thanks to the expertise of Tempus 3D.    Conclusion:   By adopting a digitized workflow and partnering with Tempus 3D for 3D printing, clinicians are enhancing the quality of care they deliver, providing precise, custom-fitted orthotics in a fraction of the time. As technology advances, the orthotics field will continue to evolve, bringing even better outcomes for patients. Embracing these innovations is an investment in the future of orthotic care—and one that both patients and clinicians are excited to be a part of! Next week we will take a bit of a closer look at what kinds of 3D scanners can be used, stay tuned!