Current turnaround Design OnlyUnder 30 minutes Design+Print2-4 business days Full Svc7-9 days

Sign In Create Account

Your custom foot orthotic design house

No library. No best-match. No template.

Our design automation is built on 30+ years of custom foot orthotic design and corrections. It forms the shell to the scanned foot, applies your corrections, and designs pads, additions, extensions and shell modifications as prescribed.

Three levels of service for you to choose from: Design Only, Design + Print and Full Service.

I'm a clinician I'm a lab

iPhone + scanner attachment scanning a bare foot off the end of the plinth — 3D laser scan

printed shell, k1 max — 4MM MEDIAL SKIVE

shell on scan — SCAN ON ACTIVE ORTHOTIC

finished pair, top cover — Full Body (soft)

The craft is constant, whichever service you choose.

Design Only, Design + Print or Full Service, every pair starts from the same design file. That file is what makes each pair fit, repeat, hold your corrections and flex as prescribed.

good to go. 🍃🍃🍃

Fit

The shell follows the scanned foot contours — not a best-fit template, and not a generic arch profile stretched to fit.

Repeatability

Refills are printed using the original design files. Posting angles, pad placement and trim lines don't drift between the first pair and the fourth.

Control

Every correction is a precise value in the file — a posting angle, a thickness, an extension length. Designed in CAD, artfully and with great accuracy.

Material

Shells are carbon-fibre nylon (PA12-CF10) or 95A TPU, chosen by device type. Additions and extrinsic posts are TPU, printed at the density each one needs: firm where it supports, soft where it cushions. Each part has a house default, and you can change it on the order.

Service levels

Design Only is the core. The other two are there when you need them.

The design files print easily on a Creality K1 Max in your clinic, or send them to your 3D print service, such as Forge Labs or Hubs (HP MJF: a smoother finish, at a higher cost per pair). Either way, we'll guide your choice of printing material. Not printing yet? We'll print for you. Choose shells and additions to assemble and cover yourself (minutes of work for your existing staff), or finished pairs, ready to dispense.

Core — Recommended Clinicians + Labs

Design Only

We design, you print — on your own printer, or by sending the files to a print service. You get the 3D design files for the shell and its snap-fit additions, plus guidance on printing material. Add and you just press print. Print in-house and cost per pair drops to a tiny fraction of what you pay now. Printing and assembly take minutes of staff time, with no new hires.

You receive

3D design files. Print-ready setup optional

Design turnaround: Under 30 minutes

Current typical time, not a guarantee

Bridge — Printer on order Clinicians + Labs

Design + Print

We design and print for you. Every component: shells, TPU pads, extensions, additions. You receive them ready to assemble, then cover in your own space: a few minutes' work for your existing staff. Expect real savings over full-service lab pricing, with no printer to buy or run.

You receive

Printed shells and additions, ready to assemble

Turnaround: 2-4 business days

Current typical time, not a guarantee

Fallback — Not printing Clinicians

Full Service

We design, print, assemble, finish and quality-check the pair, then ship it ready to dispense. The design is in the same files you'd print yourself later.

You receive

Finished orthotics, ready to dispense

Turnaround: 7-9 days

Current typical time, not a guarantee

Create account to see pricing.

Artful engineering

The shell is formed onto the scan, the way a shell is vacuum formed over a positive.

There is no library and nothing is approximated. The shell takes on the patient's own contours: heel cup, medial and lateral arch, met raise region. Then, and only then, are corrections designed in.

A custom orthotic is as much art as engineering: shaped artfully to the foot, built to change forces and pressures acting on it. Our automation builds proven correction logic into every design.

scan mesh, unmodified

01 — Scan in

Your laser scan arrives as-is. We don't smooth away the arch, and we don't swap it for the nearest stock shape.

shell conformed to mesh

02 — Shell conformed

The shell surface is formed against the mesh so contact is continuous. The shell arch shape is exactly the foot's arch shape. From here, cast dressing, expansion and order specs are designed.

rearfoot posting, 4° varus

03 — Posting as prescribed

Rearfoot and forefoot corrections are built into the geometry at the exact angle you specify — intrinsic or extrinsic.

Posting, spelled out

Posting is a precise value, set in CAD in degrees. A 4° varus post is often made as a 4 mm wedge, but degrees and millimetres aren't interchangeable: the wider the foot, the thicker the wedge needed to reach the same angle. On a 60 mm heel, 4° is about 4.2 mm; on an 82 mm heel, about 5.7 mm. We post to the angle you prescribe, so 4° is 4° on every foot.

The same 4° varus post on 60, 70 and 82 mm heels, viewed from behind: the medial edge rises 4.2, 4.9 and 5.7 mm, against a fixed 4 mm wedge.

The same 4° varus post on 60, 70 and 82 mm heels, viewed from behind: the medial edge rises 4.2, 4.9 and 5.7 mm, against a fixed 4 mm wedge.

Additions, padding, extensions

Trace lines and snap-fit features let you locate every pad and addition quickly, easily and accurately during assembly. Once snapped in, they stay put — no sliding around, even under aggressive use.

met raise — MET RAISE

morton's extension — HEEL PAD

heel spur relief — Morton's extension

top cover options — FHL Accommodation

Snap-fit assembly

No grinding. No dust. The parts already fit.

Every piece is custom to the patient and comes off the printer ready to assemble. Placement pins and outline traces put each part exactly where it belongs, so assembly is easy, fast, and accurate — at the bench, with no grinder in the room.

Exploded view of a 3dp orthotic: the shell, a separate heel pad with two snap-fit pins, a separate met raise pad located by a raised outline, and the forefoot bottom cover with snap-fit pins that press into holes in the shell; an extrinsic rearfoot post is built into the shell.

01 — Snap

Press the heel pad and forefoot bottom cover onto their pins. The raised outline on the shell shows exactly where the met raise sits.

02 — Bond

A light coat of 3M 77 Multi-Surface spray adhesive, available on Amazon, holds every piece in place.

03 — Cover

The forefoot bottom cover is already shaped and sized. Apply the top cover, then trim to the shell and FF bottom cover.

No grinding

Posts, pads, and covers are designed to size. There's nothing to grind to shape.

No dust

No grinder means no dust collector, no masks and no noise in your clinic — and cleanup is quick and easy.

Very little waste

The only scrap is the top-cover offcut left over from trimming to shape. No grinding dust or shavings means far less waste heading to landfill.

good to go. 🍃🍃🍃

In-office production

One printer, one dryer, and the files we send you.

A Creality K1 Max and a Space Pi filament dryer on a bench in the back. It runs on our validated print profile. No new hires, no new room, no learning to be a manufacturer. Busier clinic? Add a second printer, one for PA12-CF10 and one for TPU, and skip the filament changes.

Per print bed

1–3 pairs

Nested on the K1 Max's 300 mm bed.

Print time per pair

Shells3–5 hrs
TPU parts1–3 hrs
Full Body, with additions and padding8–12 hrs

Per month, one printer: about 34–45 complete pairs, running regular business hours.

Staff time

Minutes

When the print finishes: remove the parts, assemble and cover the pair.

Cost per pair

Far less

A tiny fraction of what an outside pair costs you today. Even at a few pairs a month, your setup pays for itself within a couple of months. Create account to see pricing.

k1 max + filament dryer on clinic bench

What we send

The 3D design files, ready for any printer or print service. Add print-ready setup and they arrive set up for your Creality K1 Max: just press print.

See the clinician path

For clinicians

Design Only, printed in your office.

We design every pair; you print it on a K1 Max in the back room. No printer yet? Design + Print ships the printed shells. Your existing staff assemble and cover them in-house in minutes, for a fraction of full-service lab pricing.

Clinician services →

For labs

Design capacity, on tap.

Design Only to your specifications, under your brand — order form, invoicing and dashboards included. We don't touch your accounts.

Lab partnerships →

Try one pair. The fit will do the talking.

Enter your prescription, attach the patient's scans and submit. Choose Design + Print and the parts arrive ready to snap together — you'll see first-hand how easy assembly really is.

good to go. 🍃🍃🍃

Create an account Or talk to us first

A free account gives you

Full price list for every service level Warranties and policies Your clinician dashboard:

Live order form
Your patient list
Refill, replace and warranty
Order tracking, from payment to shipped
Direct messaging with the lab
Invoices and statements
Your profile and order defaults

Contact

Talk to us first.

Questions about service levels, printing or a first pair. A person reads every message and replies by email.

Confidentiality

Who you work with is private. We keep it that way.

Clinicians and labs both trust us with information they'd never want in the open: patient scans, prescriptions, order volumes, and the simple fact that they work with us at all. All of it is confidential, permanently and without asking.

We don't disclose

No partner list, no logo wall, no case studies naming you. If you want to tell people you work with us, that's your announcement to make.

We don't sell data

Scans, prescriptions, order histories and patient information are never sold, licensed, brokered or used to train anything for anyone else.

We don't discuss accounts

Not with other partners, not with your competitors, not as a sales reference. Volumes, pricing and methods stay inside your account.

We don't advertise you

Your name never appears in our marketing, and our name never has to appear on your product. Privacy is the default, not an upgrade.