Implementing Additive Manufacturing in Orthopedic Shoe Supply Chains—Cost and Lead Time Comparison

Highlights: What are the main findings? For current supply chain disruptions, only AM production of entire orthopedic shoes is viable. Hybrid solutions, where only components or tools are AM produced, seem not viable. Low prices and a perfect digital design are hard requirements for an AM SC. What is the implication of the main finding? Research how traditional craftsmanship can be embedded into digital designs is required. Introducing AM may not be sufficient for SC performance improvement in orthopedic shoes. More mature and developed AM technologies in future can improve lead time significantly. Background: Additive manufacturing (AM) for patient-specific medical care products offers great opportunities. However, evidence about the supply chain (SC) performance impact based on empirical data is limited. Methods: In this case study, we gathered real-life data about a traditional manufacturing orthopedic shoe SC and developed future scenarios in which AM is introduced at various points and with different degrees of penetration in the SC. Results: Presently, AM can only replace traditional manufacturing of tools and shoe components at a higher total cost. However, with maturing technology, the complete AM production of orthopedic shoes is expected to become feasible. Theoretically, that could disrupt existing SCs, eliminating 70% of the SC steps, improving SC lead time by 90%, and altering SC relations. However, certain thresholds currently prevent disruption. Specifically, the AM of complete orthopedic shoes has to become possible, manufacturing prices have to drop, and traditional craftsmanship has to be integrated into the digital product design. Conclusions: A framework for transition pathways, including directions for future research, is formed. Findings provide valuable insights for scholars and decision makers in the patient-specific products industry, health insurance providers, and healthcare policy makers to be better prepared by adjusting SC designs, relationships, and remuneration programs while AM technology develops towards maturity.