From Concept to Creation: Inside the Digital Workflow of Limber's Prosthetic Manufacturing Process
- Samantha Obligacion
- Jul 3
- 3 min read
Limber is a medical device company on a mission to help clinicians make high-quality prosthetic devices more accessible—faster, easier, and with greater accuracy. By combining cutting-edge technology with practical clinical tools, Limber is transforming how transtibial prostheses are created. At the heart of this innovation is a fully digital workflow designed to streamline the production of personalized, 3D-printed prosthetic limbs like the UniLeg. In this blog, we’ll walk through every step of the Limber workflow and discuss its benefits for clinics and patients alike.
Starting the Process: A Clinician-First App
It all begins with the Limber Clinical App, a proprietary iPhone application that puts control in the clinician’s hands. Within the app, users can create new orders, track status updates, access marketing resources, and follow step-by-step tutorials—all in one place.
To start a new order, clinicians simply navigate to the Home tab and select “Create New.” The app then generates a unique, non-identifying “license plate” code for tracking purposes. Importantly, Limber intentionally avoids collecting any personally identifiable information (PII), enhancing both privacy and ease of use.
From there, clinicians select one of three guided workflows:
Copy-Existing – Scan a current prosthetic device and let Limber replicate and improve it.
Self-Rectified – Create a new socket following traditional self-rectification methods.
Limber-Rectified – Most often used internationally, Limber handles rectification remotely.
The Copy-Existing workflow, in particular, saves valuable clinical time by offloading the manual work to Limber’s advanced digital system.
Customization Through Digital Modeling
Next, the clinician selects the type of positive model to use: a digital file, a physical model, or, if needed, an alginate mold. The app then guides the user through adding patient details like height, weight, and functional level (K-level). Clear instructions for capturing photos ensure visual data is consistent and accurate.
Scanning the Prosthesis: Seamless and Accurate
With the basic data captured, it’s time to scan. For the Copy Existing workflow, Limber requires two scans: one of the prosthesis and one of the positive socket. With just those two scans, Limber is able to accurately re-create the prosthesis, including socket fit and alignment.
Clinicians can use whatever scanning solution they want provided it generates an industry standard OBJ file. However, the Limber Clinical App is tight integrated with Comb, one of the most popular and effective iPhone scanning solutions. Once the scans are complete, the Limber Clinical App requests data around suspension and foot configuration, they you are done. The data is sent directly to Limber’s FDA-registered manufacturing facility, where the production process begins.
At the facility, Limber’s certified prosthetist reviews every model to ensure it meets the highest standards. This digital approach overcomes traditional barriers such as material shortages and costs, human error, and geographical limitations, making quality prosthetics accessible to clinics anywhere in the world.
3D Printing Meets Personalized Prosthetics
Once verified, each UniLeg is manufactured using advanced 3D printing techniques and Limber’s proprietary material. These materials make the prosthesis lightweight, strong, and durable — ready for everyday life and beyond. Production is completed in a matter of days, a sharp contrast to the slower, more labor-intensive traditional methods.
Limber also includes 3D-printed soft inserts and distal end pads at no extra cost. These components, printed from a Pelite-like flexible material, ensure comfort and an optimal fit.
Thermoforming for the Perfect Fit
Even after the UniLeg is printed, customization doesn’t stop there. Clinicians can further fine-tune the device using the Limber Thermoformer, which enables on-site adjustments to height, rotation, and translation in multiple directions. These changes are logged in the Limber app, ensuring that future reprints reflect the latest specifications and meet patient needs.
Boosting Clinical Efficiency and Patient Outcomes
Limber’s fully digital workflow is designed to enhance clinical operations while improving patient care. Integration with electronic patient management systems allows for real-time tracking and reduced administrative burden. With less manual labor required, clinicians can focus on what they do best—caring for patients.
For amputees, the result is a prosthesis that fits better, feels lighter, and is delivered faster. For clinics, the UniLeg represents a scalable opportunity to increase revenue and satisfaction without additional overhead.
A New Standard in Prosthetic Manufacturing
From the first scan to the final fitting, Limber is redefining how prosthetics are made and delivered. By embracing modern tools like 3D printing, app-based workflows, and cloud integration, we are ushering in a new era of precision, speed, and accessibility in prosthetic care.
To explore more about Limber’s innovative approach and the UniLeg’s potential, visit our website at limberprosthetics.com.
