Why Would You Choose Milling Over Direct 3D Printing in 2025 for Your Orthotic & Prosthetic Applications?
, by Hugh Sheridan, 4 min reading time
In the fast-evolving landscape of digital fabrication for orthotic and prosthetic (O&P) device production, it’s tempting to assume that 3D printing is the inevitable future. Yet in 2025, milling remains a core—and often superior—technology for many workshops worldwide.
In the fast-evolving landscape of digital fabrication for orthotic and prosthetic (O&P) device production, it’s tempting to assume that 3D printing is the inevitable future. Yet in 2025, milling remains a core—and often superior—technology for many workshops worldwide.
The ORTHO EVO 2025 from Satres illustrates exactly why. After setting the standard since 2020, with over 100 orthopedic labs using it to produce more than 100,000 custom aids, the newly upgraded ORTHO EVO 2025 brings automation, intelligence, and reliability that even the most advanced 3D printers struggle to match.
Precision, Speed, and Proven Repeatability
Milling has always excelled in consistency and accuracy. The ORTHO EVO 2025 builds on this with improved performance, delivering faster cycles, cleaner finishes, and tighter tolerances—crucial for sockets, AFOs, KAFOs, and spinal braces where fit is everything. Unlike many direct 3D printing methods that depend on layer-by-layer adhesion, milling cuts directly from solid polyurethane blocks, eliminating risk of print failures or surface artifacts.
Cleaner, Smarter, More Automated
The 2025 version of ORTHO EVO introduces:
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Automatic axes lubrication, ensuring continuous operation with minimal intervention.
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Automatic protection against polyurethane dust, extending machine life and reducing maintenance downtime.
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Upgraded software with Industry 4.0 connectivity, integrating your lab with digital traceability, production analytics, and centralized control.
This level of automation means technicians spend less time maintaining machines and more time designing and delivering patient-ready solutions.
Compact and Cost-Effective
For many small and mid-sized workshops, space and cost efficiency remain critical. Milling systems like ORTHO EVO offer a compact footprint and an all-in-one plug-and-play setup. With minimal calibration requirements and predictable material costs, labs enjoy a faster return on investment compared to 3D printers that require ongoing filament or resin calibration, support structures, and post-processing.
Milling vs. Direct 3D Printing: A 2025 Reality Check
| Factor | Milling (ORTHO EVO 2025) | Direct 3D Printing |
|---|---|---|
| Surface Finish | Smooth, ready for lamination | Requires sanding or coating |
| Speed for Large Models | Fast and consistent | Slower for full-scale sockets |
| Material Cost | Predictable polyurethane blocks | Variable resin/filament costs |
| Maintenance | Automated lubrication & dust protection | Frequent nozzle, resin, or filter replacement |
| Production Reliability | 99%+ uptime | Print failures still common in FDM/SLS |
| Integration | Industry 4.0, traceability built-in | Dependent on third-party slicers & IoT layers |
Designed for the Demands of Real O&P Production
Orthopedic milling remains a proven industrial process, engineered for high-volume, medical-grade output. The new ORTHO EVO 2025 pushes this tradition further—bridging manual craftsmanship with the automation and data connectivity of the future.
For clinics and workshops looking to expand production, reduce downtime, and maintain absolute reliability, milling is not a step back from 3D printing—it’s the smart step forward.
About ORTHO EVO 2025
The latest generation from Satres redefines orthopedic milling with automation, safety, and smart control. It’s fast, precise, and built for the next decade of custom orthotic and prosthetic device manufacturing.
Key Highlights:
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Automatic axes lubrication
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Polyurethane dust protection
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Industry 4.0 integrated software
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Compact all-in-one design
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Proven performance across 100+ labs
Make your orthopedic lab more competitive.
Invest in technology that’s built for precision, productivity, and the future of custom device manufacturing.
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