The machine does the routine engineering; the human makes the clinical decision.

HomeHow It Works

Design lives in the Clonify desktop app. Below are the actual workflow steps for cranial (analysis & helmet), socket (lower & upper extremity), AFO, insoles, and splint. The web panel is for managing your clinic.

System suggestedClinician approved

The actual steps on desktop

The lists below are the actual desktop steps. Not a four-box slogan.

Head Socket Analyses

Head analysis (HSC)

The scan is imported, aligned to the anatomical plane, sliced, photographed and compared with a previous scan. The PDF report comes from this workspace.

1
Import
An open-format (PLY/STL/OBJ/CPX/VTP) head scan is loaded; smoothing, densification and hole/shell repair run in this step.
2
Head Alignment
The model is aligned to the anatomical plane. Ear landmarks are the reference for later trim and helmet lines.
3
Head Slicer
CVAI, cephalic index, circumference and diameters are measured on Z slices. Sample report: CVAI 6.1% · CI 87.6% · CVA 8.6 mm · circ. 438.1 mm.
4
Cranial Photo Capture
Clinical photographs are bound to the same file as the scan and embedded in the report.
5
Head Comparison
Two scans side by side: anthropometry, asymmetry, volume and a live slice. The PDF report is produced here.

Head Socket Design

Helmet design (HSD)

From the aligned scan: target shape, clearance, shell, assembly and STL export. Deformity type is not a separate step; CVAI/CI are measured in the helmet-design step.

1
Import
The same scan file is opened for helmet design.
2
Head Alignment
Alignment from analysis is kept or repeated.
3
Cranial
The current head is measured. A future head is built from target CVAI/CI; the helmet inner surface stays at least 10 mm outside the scan (growth allowance).
4
Zone / Clearance
Active (1.5–2.5 mm) and passive (6–8 mm) clearance bands are applied to the target shape.
5
Shell / Offset
Liner inner-surface offset and an editable trim loop. The cut is separate: Apply Crop.
6
Assembly
Hole, lid, dual symmetric lock mechanism and circumferential separation cut tools in one step, tabbed.
7
Validate / Export
Fit check, orthotist approval, clinical report and STL export.

AFO

AFO (3D-print & CNC mold line)

Steps of the desktop AFO workspace: direct 3D-printed shell and CNC positive mold step for thermoforming workshops.

1
Import
Leg and foot scan (PLY/STL/OBJ/CPX/VTP) is loaded.
2
Alignment
The model is aligned to the reference axes.
3
Toe rotation
Foot/toe orientation is adjusted on the scan.
4
Toe cap
Toe-cap geometry is added.
5
Crop
Unwanted regions are cropped.
6
Sculpt
The surface is raised or carved with a brush.
7
Grow
The surface is thickened into a solid.
8
Edge flare
Edges are flared outward and softened.
9
Strap slot
Strap channels are cut.
10
Holes
Ventilation / connection holes.
11
Volume
Volume and thickness check.
12
Export
The finished model is exported as a file or report.

Insoles

Steps of the desktop Insoles workspace: region selection, shell, surface sculpting, and 3D print / CNC blank production export.

1
Import
The foot scan (PLY/STL/OBJ/CPX/VTP) is loaded.
2
Insole region
Metatarsal and heel regions are selected.
3
Crop
Insole bounds are cropped.
4
Insole shell
The insole shell is built.
5
Sculpt
The surface is edited with a brush.
6
Export
3D print or CNC blank milling production file is exported.

Lower Extremity

Lower extremity / socket (LE)

Prosthetic socket geometry and CNC mold/print steps from transtibial and transfemoral residual-limb scans.

1
Import
Lower extremity residual-limb scan (PLY/STL/OBJ/CPX/VTP) is loaded.
2
Alignment
Aligned to the reference axes.
3
Limb lengthening
Cut height and lengthening are applied.
4
Sculpt
Regional raise / carve.
5
Ring
Reduction rings are added.
6
Crop
The trimline is cropped.
7
Edge flare
Edge flare.
8
Edge curl
Open edges are curled in millimetres.
9
Grow
The shell is thickened.
10
Anchor extension
The attachment block is placed.
11
Volume
Volume check.
12
Export
File or report.

Upper Extremity

Upper extremity / socket (UE)

Prosthetic socket geometry from transradial and transhumeral residual-limb scans: flange, reduction rings, fine sculpting, and production export.

1
Import
Upper extremity residual-limb scan (PLY/STL/OBJ/CPX/VTP) is loaded (transradial / transhumeral).
2
Alignment
Model is aligned to anatomical reference axes.
3
Crop
Socket boundaries and trimline are cropped.
4
Flange
Proximal flange and anatomical transition geometry are built.
5
Ring
Stabilization and reduction rings are added.
6
Sculpt
Pressure and relief areas are sculpted with a brush.
7
Volume
Wall thickness and internal volume are verified.
8
Export
Export file or clinical report for diagnostic or definitive socket.

Splint

Hand splint

Desktop splint workspace: pressure-mapped volar splint workflow from forearm and hand scans.

1
Import
Forearm and hand scan (PLY/STL/OBJ/CPX/VTP) is loaded.
2
Finger rotation
Finger orientation.
3
Crop
Bounds crop.
4
Palmar cut
Palmar cut line.
5
Sculpt
Brush.
6
Grow
Thicken.
7
Edge flare
Edge.
8
Bridge
Bridge geometry.
9
Strap slot
Strap channel.
10
Holes
Holes.
11
Volume
Volume.
12
Export
Export.

Transparency

Which steps are automatic, which decisions stay with the clinician?

In medical software, trust starts with not hiding what is automated. Every row in this table is how the product works today.

Autonomous

Head alignment

Seated on the anatomical plane; the clinician can review and correct.

Autonomous

Slicing and measurement

CVAI, CI, circumference and diameters automatic on Z slices. Sample report: CVAI 6.1% · CI 87.6%. Does not diagnose.

Autonomous

Comparison and PDF report

Two scans side by side; anthropometry and slice. The report leaves this step.

Semi-autonomous

Target head and growth allowance

The future head and helmet inner surface are built from target CVAI/CI and a 10 mm allowance; sliders stay with the clinician.

Semi-autonomous

Clearance and trim line

Active 1.5–2.5 mm, passive 6–8 mm. Trim loop is edited; the cut is separate (Apply Crop).

Always human

Regional shaping

Regional shaping is a clinical decision; the software gives millimetric tools.

Always human

Approval and STL

After the fit check, no production file leaves without orthotist approval.

Always human

Diagnosis

A classification suggestion exists (plagio/brachy/scapho); diagnosis belongs to the physician.

Transition

Transition plan (a target, not a measured SLA)

Week 1

Setup and training

Desktop setup and team training. Duration depends on the clinic; ≤8 hours is a talking target, not a published average.

Weeks 2–3

Parallel production

The plaster flow is not shut down; selected cases run both methods side by side.

Week 4

Digital line as primary candidate

The team starts designing unassisted. Remote co-design for the first devices can be arranged.

If you have no printer

The approved STL goes to the clinic printer. If you don't have one, the file is sent to partner production and the device is delivered to your clinic.

See the process on your own case

Bring a scan of your own patient to the demo; let's walk the four steps together.

Request a 30-Minute Demo Review Sample Report (PDF)