How to Post-Process a 3D Printed SMO

Once your SMO (Supra-Malleolar Orthosis) has been printed, it requires finishing work to ensure proper fit, comfort, and durability. Follow these steps to post-process your SMO:

1. Remove the Supports

• Carefully pull or cut away the bottom and front supports from the print.

2. Clean Off Extra Threads

• Use clippers to remove any stray threads or stringing left from the print.

3. Cut the Front Seam

• Cut a straight, symmetrical line down the front of the SMO.

4. Round the Toe

• Trim the edges off the front of the SMO to create a rounded toe shape.

5. Smooth the Seams and Toe

• Use a sanding or grinding tip to smooth down the seam you just cut.
• Grind the tip of the toe so it feels even and comfortable.

6. Shape the Toe Slope

• Grind the top of the toe to create a gradual slope.
• Thin out about a finger’s width of material. This makes the toe more pliable.

7. Cut the Foam Insert

• Trace the outline of the SMO onto a sheet of foam.
• Cut the foam to size.

8. Fit the Foam

• Place the foam inside the SMO.
• Continue trimming until it fits snugly but comfortably.

9. Check for Symmetry

• Ensure both sides are symmetrical before finalizing the fit.

10. Finish the Foam

• Smooth the edges of the foam with a foam grinder.
• Shape the bottom so it transitions smoothly, similar to a shoe insert.

11. Glue the Foam in Place

• Apply liquid glue to both the foam and SMO contact surfaces.
• Let the glue dry until tacky.
• Insert the foam into the SMO and press firmly into place.

12. Final Adjustments

• Shave off any excess foam.
• Grind the tip of the foam thin (about a finger’s width) to add a slight slope and extra pliability.

Updated on: 18/08/2025