3D Printed Pediatric Orthotic Solutions
Bringing more than 25 years of Surestep clinical experience to 3D printed orthotic care.
Our 3D Printed Products
Sprout3D® Cranial Remolding Orthosis
A single, growth-accommodating CRO for the full course of treatment. It’s FDA 510(k)-cleared and used by more than 350 clinics nationwide.
- Indication-specific trim lines for plagiocephaly and brachycephaly, plus a standard circular opening
- Precision fit maximizes patient comfort and minimizes in-clinic modification
- Hinge opening that opens wider for easier modification
- 20% lighter than traditional CROs (internal data on file)
SMO3D™ Family
Built on the compression-based approach behind nearly 2 million Surestep SMOs, reimagined in 3D.
- Flexfield™ technology expands and contours around the malleoli
- Perforated, lightweight PA12 nylon with dyed color that lasts the full treatment
- Narrow heel post and thin profile for easier shoe fit
- Available in: SMO3D, Toe Walking SMO3D, Open Heel, and Toe Walking/Open Heel combination
Why Surestep 3D?
Surestep owns the 3D printing process in-house from start to finish. Rather than turn to print farms, we invested in our own printing equipment, and we have the engineers and team to run it, from the printers to vapor smoothing and dyeing.
We are committed to completing your order on time, every time, which is why we don’t rely on a third-party printer. Because we have greater control over our work in progress and materials ordering, we can control fabrication times to ensure your patients get the care they need.
Frequently Asked Questions
What makes Sprout3D different from traditional CROs?
What are the clinical outcomes?
In a retrospective matched cohort analysis conducted by the Hanger Institute, Sprout3D showed a 10-percentage-point greater improvement in cranial vault asymmetry index (CVAI) compared to traditional thermoformed CROs. That translates to faster, more measurable correction.
How much lighter is Sprout3D?
20% lighter than traditional CROs.1
1. Internal data on file.
What is the fitting time difference?
Eight out of 10 orthotists claim fitting time has been reduced by 15 minutes or more compared to traditional CROs2, leaving more time to educate and prepare families for cranial remolding treatment.
2. The survey included 80 clinicians who provide Sprout3D.
What is the turnaround time?
Seven business days plus two-day shipping. There’s no rush option for Sprout3D. However, you can choose to pay for upgraded overnight shipping.
What customizations are available?
Sprout3D features indication-specific trim lines designed for plagiocephaly, brachycephaly, or the option for a standard circular opening. The innovative hinge design allows wider opening for easier modification if needed. Treatment-specific design means less in-clinic tweaking and more clinician-family time.
How easy is it to modify Sprout3D?
Very easy! The hinge design opens wider than traditional CROs, and the 3D-printed structure allows easy modification without compromising integrity. Perforated foam can be easily adjusted for ventilation or comfort.
What is the material composition?
Sprout3D is 3D Printed from PA12 Nylon and has hypoallergenic perforated foam. No latex. The design supports a secure, intimate fit without irritation.
Is Sprout3D FDA-cleared?
Yes. It’s FDA 510(k)-cleared and meets the highest regulatory standards for cranial remolding applications.
Can Sprout3D be used for the entire treatment course?
A single orthosis is required for the majority of cases from mild to severe plagiocephaly and brachycephaly. No need to transition devices as the infant grows.
How does the precision fit reduce follow-up?
The 3D-printed precision fit minimizes helmet rotation—a common source of discomfort, after-hours calls, and additional appointments. Better fit means better patient outcomes and fewer adjustments.
What is the warranty policy for Sprout3D?
Please reach out to our team at [email protected] if you have questions about replacing a Sprout3D.
What is the clinical foundation of SMO3D?
How does 3D printing change the clinical design?
3D printing enables increased precision and features impossible with thermoplastic. The Flexfield™ technology contours around the malleoli using lattice structures, flexing and expanding in targeted areas during movement to accommodate prominent malleoli while naturally recovering its original shape afterward. Variable wall thickness lets us apply support exactly where patients need it.
When should I choose SMO3D over the standard thermoplastic SMO?
SMO3D is ideal for patients ≤80 lbs. where breathability, shoe fit, or wear compliance are priorities. The perforated design manages heat, the narrower heel post fits standard footwear more easily, and the lightweight construction encourages consistent wear. If your patient weighs ≤80 lbs., needs significant customization, or requires rush fabrication, the thermoplastic SMO is the better choice.
What is the turnaround time?
The SMO3D and Toe Walking SMO3D turnaround time is five business days; the Open Heel variations have a 10-business day turnaround time. There’s no rush option for SMO3D, so plan accordingly. For rush orders, the standard Surestep SMO remains available.
How customizable is SMO3D?
Due to the manufacturing process, SMO3D is more standardized than the thermoplastic line. Standard trim lines are available through the ordering portal. Heat adjustments and minor strap/chafe modifications are possible (contact customer service at 877.462.0711). If you need modifications beyond that—different heel designs, reverse trim lines, clubfoot modifications—the thermoplastic SMO offers more flexibility.
Can I trim back the perforated area?
No. Trimming compromises device integrity. If patients have fit concerns, contact customer service at 877.462.0711 for troubleshooting.
Can I heat modify the SMO3D?
Yes. We recommend using a small butane torch to heat the area lightly for a few seconds prior to adjusting. Do not use a large butane torch. If using a heat gun, use it with a condenser. Heating an area for too long can result in melting the plastic, bubbling at the surface, or burning the dyed layers off. For more information, download the SMO3D Modification Guide.
What is the weight limit for SMO3D?
Less than 80 lbs. We recommend using the standard Surestep SMO or the Big Shot thermoplastic model for patients > 80 lbs.
How durable is the PA12 nylon material?
PA12 nylon is durable for the full treatment course. Color is dyed instead of painted, so it resists fading and chipping with everyday wear. If modifications such as trimming or grinding are performed, the gray base layer will show.
What is the warranty policy for SMO3D?
Surestep has a 90-day remake policy for all custom devices. A remake is warranted for any manufacturing defect or in the case of sudden growth or inadequate fit and function. Surestep reserves the right to charge additional fees when deemed necessary.
Learn On-Demand
Interested in learning more about the SMO3D or Sprout3D? Surestep offers free, on-demand courses that cover key features, case studies, fitting tips, and more: