Digital Manufacturing is Here!

Cascade Dafo has spent the last three years developing a digital manufacturing process to complement our traditional manufacturing methods. Rather than shipping a cast to us, practitioners can now scan and upload digital files to www.cascadescans.com. This can eliminate days from the time it takes to receive a finished brace. Of course, you can continue to cast for braces and ship us the cast; digitization is simply another option for those with a digital 3-D scanner. Digitization offers a win-win—lower shipping costs and less time to wait for the brace to reach your patient.

The bottom line—whether you upload a scan or ship us a cast, you’ll receive our trademark high quality and intimate fit. And sending us your scans saves you time and money.

If you have questions, please ask Denny Organ (dennyo@dafo.com) or Tech Support (technicalsupport@dafo.com) — 800/848-7332. 

How It Works
	Scan Use one of the methods described below to capture the data needed for the custom DAFO. Upload 3D-scanned images (.stl or .ssn file formats) and the order form(s) to www.cascadescans.com.		Benefits Significantly reduced turnaround time especially to the East Coast and abroad No inbound shipping cost Same excellent Cascade quality and warranty CAD/CAM enhances our ability to produce very consistent and reliable results allows very precise and traceable changes to the original shape Digital orders enter the lab manufacturing process within hours of being received Digital files are stored electronically if a redo is ever required, we can make changes with precision and speed
	Modify Our modification team works on each custom project individually, applying the same standard Cascade build-ups and modifications as we do in our manual process.
	Carve Our custom-designed carving machines shape the mold that will be used to produce the custom DAFO with extreme precision in a matter of minutes.
	Finish The molds then follow the same quality Cascade process for padding, plastic pulling, bottom treatment, straps, and final inspection.

Types of Data Capture

TYPE OF DATA CAPTURE	ADVANTAGES	DISADVANTAGES
Scan of the plaster positive Fill the cast with plaster and then scan the plaster positive.	This method provides the best possible image.	Additional time commitment to fill and strip the cast.
Scan of the actual patient ‘Free form” or put the foot on an acrylic stand (able to scan the entire foot).	Excellent image capture is possible (if the patient can sit still).	You can’t use your hands to make the bio-mechanical corrections at the same time you’re taking scans.
Scan inversion Cut the cast in half; scan both sides and digitally “stitch” them back together. * If you would like to send us scan inversions, please first send a test file so we can ensure there’s enough detail to make a brace with excellent fit.	Can provide a good “interior” view of the cast without filling.	This method may “over-smooth” the data; creating an image without the ideal amount of detail.
Scan of the outside of the cast	If the cast thickness is uniform and the cast is corrected well, we get good results.	If the thickness of the cast varies from top to bottom or if the foot is left in a poor and uncorrected position, we may have difficulty creating an excellent fit.
Measurements Foot length, met-head width and circumference, circumference heel back to instep, circumference at the malleoli, circumference at the calf, and any other details necessary for accurate brace construction.	This method works well when a child is difficult to cast or other complications make it impossible to cast or scan.

Q&A: Digital Manufacturing

Q:  How long does it typically take to make braces produced by Cascade’s digital manufacturing process?
A:  On average, three to four days from receipt of scan to outbound ship date—and our manufacturing team is continually working to reduce turn around even further.

Q:  Are braces produced by Cascade’s digital manufacturing process also covered by Cascade’s full 90-day warranty?
A:  Yes. All of our braces are covered by Cascade’s warranty, including those produced from scans.

Q:  Are braces produced from scans still covered by insurance?
A:  Yes! They are still custom-made ankle-foot orthoses, each modified individually by our modification team.