Custom 3D-printed orthotics — designed in our own lab
Most clinics outsource their orthotics to a third-party lab. We don't. Every Lower Limb orthotic is designed from clinical 3D scan data and manufactured at our sister company, Réalta Labs — a precision SLS 3D printing facility in Co. Down, Northern Ireland. Paul McMullan oversees every orthotic design from the lab, with the prescribing clinician retaining full clinical control of the case.
From clinical scan to custom orthotic
No foam impressions. No plaster casts. Direct 3D scan data flows from your clinical assessment into the prescription, then to the printer.
Scan
During your assessment, your specialist podiatrist captures the precise geometry of your feet using a clinical 3D scanner. No messy impressions.
Prescribe
The clinician completes a digital prescription — chassis type, shell geometry, posting angles, modifications — based on your assessment findings.
Print & Receive
Réalta Labs prints your orthotics on a Formlabs Fuse 1 SLS printer in PA11 bio-nylon, hand-finishes them, and dispatches within days.
Vertical integration matters in orthotic prescribing
The traditional model
A foam impression or plaster cast is taken in-clinic, posted to a third-party lab — often abroad — where a technician interprets the prescription, mills or thermoforms a generic shell, and posts it back. The clinician sees the orthotic for the first time at the fitting appointment.
If something's off, the cycle repeats. Lead times are 4–6 weeks or longer. Margin and clinical control sit with the lab.
Our model
Your scan goes directly from the clinic to our sister company, Réalta Labs — a precision SLS 3D printing facility in Co. Down. Paul McMullan oversees every orthotic design personally; the prescribing podiatrist controls every clinical parameter. Sub-millimetre fidelity is preserved through manufacture. Dispatch within days, not weeks.
If a revision is needed, we own the data, the printer, and the clinical reasoning — so we fix it fast.
Conditions where custom orthotics may help
Custom orthotics are only effective when correctly indicated. Your assessment will determine whether they're appropriate for your condition — or whether another treatment pathway is more suitable.
Frequently asked questions
How much do custom orthotics cost?
Pricing is provided at your assessment based on your clinical prescription. Because we manufacture in-house at Réalta Labs we avoid third-party mark-ups. The €80 / €160 assessment fees are separate from the orthotic supply cost.
How long do they take to manufacture?
Réalta Labs prints, hand-finishes and dispatches within days. Specific turnaround for your prescription will be confirmed at your assessment.
How long do they last?
PA11 bio-based nylon is a durable polymer designed for daily clinical use. Lifespan depends on activity, footwear and how the orthotic is used — most patients get years of use from a well-fitted prescription.
Can I use them in different shoes?
Most prescriptions are designed for general use across multiple shoe types. If you need orthotics for very specific footwear (cycling shoes, ski boots, dress shoes), discuss this at your assessment so the prescription accounts for it.
What if they need adjusting?
Because we own the lab, the data, and the prescription, revisions are straightforward. Follow-up review appointments confirm fit and allow any adjustments to be processed quickly.
Do you take foam impressions or plaster casts?
No. We use a clinical 3D scanner to capture the geometry of your foot directly. This is faster, more accurate, and produces a digital file that goes straight into the prescription workflow without information loss.
Ready to find out if orthotics are right for you?
Start with an assessment. No referral needed.
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