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.
The software does the routine engineering; the clinician makes the clinical decision.
HomeHow It Works
Below are the steps you follow in Clonify for cranial (analysis and helmet), socket (lower and upper extremity), AFO, insoles and splints.
System suggestedClinician approved
The steps in the app
Each workflow is listed in the order you follow in the app.
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 is also produced here.
- 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. CVAI/CI are measured during helmet design.
- 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
The liner inner-surface offset and an editable trim loop are set; the cut itself is made separately with Apply Crop.
- 6
Assembly
Tools for holes, the lid, a dual symmetric lock mechanism and a circumferential separation cut sit in this step, each on its own tab.
- 7
Validate / Export
Fit check, orthotist approval, clinical report and STL export.
AFO
AFO (3D-print & CNC mold line)
Two production routes for the AFO: a shell for direct 3D printing, or a CNC positive mold 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
Insoles
Region selection, shell, surface sculpting and a production file for 3D printing or CNC blank milling.
- 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
From forearm and hand scan to a pressure-mapped volar splint.
- 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?
Each row shows how the product works today.
Automatic
Head alignment
Seated on the anatomical plane; the clinician can review and correct.
Automatic
Slicing and measurement
CVAI, CI, circumference and diameters automatic on Z slices. Sample report: CVAI 6.1% · CI 87.6%. Does not diagnose.
Automatic
Comparison and PDF report
Two scans side by side; anthropometry and slice. The report leaves this step.
Guided
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.
Guided
Clearance and trim line
Active 1.5–2.5 mm, passive 6–8 mm. Trim loop is edited; the cut is separate (Apply Crop).
Clinician decision
Regional shaping
Regional shaping is a clinical decision; the software gives millimetric tools.
Clinician decision
Approval and STL
After the fit check, no production file leaves without orthotist approval.
Clinician decision
Diagnosis
A classification suggestion exists (plagio/brachy/scapho); diagnosis belongs to the physician.
Transition
Transition plan (a target, not a measured SLA)
Weeks 2–3
Parallel production
The plaster flow is not shut down; selected cases run both methods side by side.
Week 4
Moving to the digital workflow
The team starts designing unassisted. Remote co-design for the first devices can be arranged.
Where is the device made?
The approved STL goes to your clinic's printer or to the fabrication lab you already work with. A partner production network is on our roadmap.
See the process on your own case
Bring a scan of one of your patients to the demo and we'll go through the steps on it together.