Release Date: October 7, 2026
Overview
This release introduces the new Hybrid Workflow. You can now design a flexible, 3D-printed inner boot and a mold for traditionally manufactured rigid shell together, and the mold automatically leaves room for the inner layer so everything fits precisely. Design selection now opens a dialog with three categories: Full Orthosis, Mold and Hybrid Orthosis. Double-shell designs also get separate color, opacity and trimline controls for each layer. On top of that, we’ve added a Cut toggle to the joint tool and automatic malleoli distance measurement, and measurements are now saved in your project files.
Key Features
Hybrid Workflow
The Hybrid Orthosis workflow combines two manufacturing methods: a flexible inner boot produced by 3D printing and a rigid outer shell produced using a mold for CNC manufacturing.
When generating the mold, the inner boot geometry is taken into account so that the rigid outer shell has sufficient space for the printed inner layer.
Design selection
The previous Select Design dropdown has been replaced by a button that opens a design selection dialog.
Designs are divided into three categories: Full Orthosis, Mold, and Hybrid Orthosis.
Full Orthosis contains standard designs, which can be either single- or double-shell.
Mold contains designs used for mold-based manufacturing.
Hybrid Orthosis contains double-shell designs where the inner layer is handled as a regular orthosis and the outer layer as a mold.
Selecting a design in the dialog does not immediately change the current workspace. The selection must be confirmed with Apply or discarded with Cancel.
Mold settings
The previous Height Limit slider and Positive Model toggle have been removed. Whether a design uses mold-based manufacturing is now determined by the selected category.
The Pipe, Flare Height, Flare Radius, and Pipe Shape controls have been moved into the Outline component. Pipe Shape is always displayed but is disabled when Pipe is turned off.
A new Offset slider has been added above Flare Height. A Mold Transition slider is available for Hybrid Orthosis designs and controls the transition between the inner layer and the scan geometry used for mold generation.
The Outline settings depend on the selected design type and layer.
Single-shell Full Orthosis designs show General Thickness and General Offset. For double-shell Full Orthosis designs, the Outer layer has General Thickness, while the Inner layer has both Thickness and Offset.
Mold designs show the mold-specific parameters. Hybrid Orthosis designs use the standard thickness and offset controls for the Inner layer and the mold-specific controls, including Mold Transition, for the Mold layer.
Layer and visual settings
For Hybrid Orthosis designs, Outer layer is now displayed as Mold layer in the layer selector and visual settings.
Double-shell designs have separate Orthosis Color settings for the inner and outer/mold layers, as well as separate opacity controls. The default color of the inner layer is gray. Color selections are stored locally in the browser.
The Show trimline control has been renamed Show trimlines and moved to the View section.
Double-shell designs have separate trimline visibility controls for the Inner and Outer/Mold layers. Trimlines of the active layer are displayed in red, while inactive-layer trimlines are displayed in gray.
Fixes and Improvements
Component changes
Component management has been expanded for Full Orthosis, Mold, and Hybrid designs.
Full Orthosis designs now allow Outline components to be enabled, disabled, added, or removed. Mold designs and the Mold layer of Hybrid designs also allow Outline, Inner, SplineGradient, and supported CustomShape components to be added or removed.
Reinforcement contours
Reinforcements now have an Is closed toggle for switching between open and closed contours.
Closed contours no longer show Custom interpolation point thickness and End-point spreading settings, as these settings do not apply to closed contours. A Rounding slider has also been added to End-point spreading.
Cut Toggle Added to Joint Tool
A “Cut” toggle is now available in the joint tool, enabled by default, allowing cut lines to be disabled while joint cavities are still created.
Automatic Malleoli Distance Measurement
The distance between the malleoli landmarks is now measured automatically and displayed in the Measurement Panel.
Measurements Saved in Project Files
Measurements placed on scans are now saved in the project file during export and remain visible after re-import.
Overlapping trimlines
Fixed a visual issue where trimlines from different layers with the same path could interfere with each other. The active layer’s trimline color is now correctly displayed.
Component group locking
Fixed an issue with component groups in Mold mode where disabling a single component could lock the entire group. The group is now locked only when all components within it are disabled.
We hope these enhancements prove valuable to your workflow. For any questions or feedback, please do not hesitate to contact your LeoShape representative, or fill out our contact form and we will get back to you shortly.