In today’s O&P landscape, carving and milling machines are revolutionizing the way clinicians and technicians create custom devices. These robotic solutions provide fast, precise, and repeatable manufacturing—freeing up time and improving outcomes for patients. Whether you’re producing foam models for orthoses or sockets for prosthetic fittings, the right carving tool can make a massive difference.

This is especially true within CAD/CAM workflows, where digital design and automated production are transforming clinical efficiency.

Let’s dive into how these machines work, how long they take, and highlight some of the best options out there, including the 3-Axis Carver, the Victor range, and more.

 

How the Manufacturing Process Works

Carving or milling starts with a digital model—often captured with a 3D scanner and modified in software like Canfit. The machine then shapes a foam or other material blank into a physical model using rotating tools. Carvers typically remove material layer by layer, following the exact geometry of the digital file.

For example, carving a transtibial prosthetic socket might take around 3 to 7 minutes, while more complex orthotic shapes like a full spinal orthosis could take closer to 10–15 minutes depending on machine speed and axis control.

The key benefits? Speed, consistency, and reduced human error. Plus, digital manufacturing allows for seamless integration with CAD/CAM workflows.

 

Axelle 3-Axis Carver: 

The Axelle is a compact, high-speed 3-axis carver designed for clinics focused on prosthetic and orthotic applications. 

With a typical carving time of 7-10 minutes for an AFO, Axelle is ideal for clinics looking to bring production in-house without the bulk of an industrial setup. It’s quiet, fast, and a true plug-and-play solution.

 

Victor Range: Ultimate Speed & Versatility

The Victor range is the powerhouse of carving. Whether you’re using the Victor Compact or the Victor Unlimited, you’re getting maximum flexibility, able to tackle complex shapes like scoliosis braces, BK/AK sockets, and even bilateral simultaneous carving.

Thanks to advanced multi-axis control, Victor carvers can reduce carving times to as low as 3–5 minutes for a socket, and roughly 10-15 minutes for large spinal orthoses. The real win is precision—Victor machines are built to handle dense foam and produce clean, ready-to-use forms that minimize finishing time.

 

 

3-Axis Carver: A Trusted Workhorse

The classic 3-axis carver remains a go-to solution in many O&P labs. It’s reliable, easy to maintain, and well-suited for carving cylindrical or relatively simple geometries like transtibial sockets or AFOs.

Though it’s not as fast or flexible as a 7-axis system, it still holds its own in daily clinical production. Expect socket carvings in the 5–8 minute range, with a high degree of consistency.

 

 

4-Axis Carver: A Step Up in Capability

The 4-axis carver adds a layer of freedom—literally. By allowing the blank or the tool to rotate around an additional axis, these machines can carve more complex geometries, improve undercut access, and speed up production.

For labs producing both prosthetic and orthotic models, the 4-axis is a great middle ground between entry-level and full industrial solutions. Carving times drop slightly versus 3-axis systems, and you gain more design freedom with the shapes you can produce.

 

Why Carving is Still King in O&P Manufacturing

Even as 3D printing becomes more common in orthotics and prosthetics, carving remains a fast, cost-effective way to produce test sockets, molds, and final-use foam models. It’s particularly valuable when time is tight and production needs are high.

Whether you’re carving a single insole or batch-producing spinal orthoses, robot carvers offer automation without sacrificing control.

 

Read also: 

Orthopedic 3D scanners

Orthopedic CAD/CAM software

Milling machines

Custom App

3d printers

Brands