3D subtractive manufacturing of casts, braces, splints and other orthoses

A three-dimensional subtractive manufacturing system configured for constructing an orthopedic orthosis from a first blank and a second blank of a plurality of blanks, the system comprising:

• a scanner configured to capture a three-dimensional model of a body part of a patient, the scanner including a light source configured to illuminate the body part and a sensor to capture images of the body part;
• a central processor configured to receive the three-dimensional model and select the first and second blanks based on the three-dimensional model, the central processor configured to convert the three-dimensional model into a computer numeric control programming file, the central processor includes an inventory management processing unit, the inventory management processing unit configured to optimize the computer numeric control programming file and production time of the orthopedic orthosis by selection of the first blank and machining parameters implementation in the computer numeric control programming file;
• and
• a computer numerical control machine configured to receive the computer numeric control programming file and an identification of the first and second blanks from the central processor, the computer numerical control machine comprised of a subtractive manufacturing machine, the computer numerical control machine configured to remove material from the first and second blanks to define first and second orthoses, the first orthosis secured to the second orthosis to form the orthopedic orthosis.