Custom Foot Orthotics

Our 3D-printed customised orthotics are lighter, stronger, and have greater flexibility than traditional polypropylene milled orthotics. With minimal printing, post production and finishing time required, we are able to keep our orthotics as cost-effective for you as possible to optimise your clinic’s returns.

Our automated processes greatly reduce human error and subjective measures, while giving you more control than ever before with the ability to vary the shell thickness in zones to allow more or less flexibility and stiffness. This means superior health outcomes for your patients by creating the exact orthotic you want, how you want it. Our 3D-printed range is also aesthetically superior to traditional materials, as no grinding or heating is required for finishing.

  • Best turnaround times in Australia
  • Streamlined processes for cost-efficiency
  • Superior in weight, strength and flexibility than polypropylene
  • Customisability like never before
  • Greatly reduced human error
  • Greatly improved identical reproducibility for those patients that want “exactly the same second pair”

Ethylene vinyl acetate (EVA) is a traditional and effective closed-cell foam material for making full-length shoe-dependant orthotics that replace shoe liners. Choose from three densities of EVA – soft, medium and hard, and one dual-density option. While EVA is a popular option for specific foot pathologies, a great benefit is the ability to modify your patient’s devices during the fitting consultation to form a bespoke shape for a particular shoe type.

We offer a shell-only option which allows other practitioners, podiatrists and orthotic labs to send their own design file for printing only. This is a time-saving and cost-saving option to purchasing a printer for those that are keen designers.

Ankle-Foot Orthoses (AFO’s) are fantastic for pathologies like posterior tibial tendon dysfunction (PTTD), foot drop, and many others that benefit from control and offloading of the foot and ankle.

The advantage of 3D-printed AFO’s is the markedly reduced turnaround and finishing time required. The scanning and designing process is where skill and expertise are now essential – and exactly what we give you here at iOrthotics.


Our 3D-printed material, PA11, is a nylon-based polymer derived from renewable resources that come from vegetable/castor oil. It has much less of an environmental impact and requires significantly less non-renewable elements in order to be produced. It has been University-tested to be superior to other polypropylene materials including:

  • Superior strength, flexibility and endurance
  • Remaining environmentally sustainable – producing 95% less waste than other 3D-printing techniques
  • Greater thermal resistance
  • Impressive elasticity
  • 40% greater tensile strength than polypropylene

Ethylene vinyl acetate (EVA) is a traditional and effective closed-cell foam material for making full-length shoe-dependent orthotics that replace shoe liners. Our EVA density comes in four densities:

  • EVA 250 (lighter – grey colour)
  • EVA 300 (medium – black colour)
  • EVA 350 (firmer – pale brown colour)
  • Dual Density (250 grey /300 teal)

The lighter densities are perfect for accommodative devices that give your patients exceptional pressure redistribution, offloading and comfort. The firmer densities combine the above with more functional support, exactly where you prescribe it.