Firefly Orthoses

Firefly Orthoses are custom-made foot orthotics used to manage lower limb biomechanics and treat musculoskeletal conditions. The production process begins with a clinician conducting a biomechanical assessment and using a 3D digital scanner to capture the anatomy of the patient's foot. This scan creates a digital model that replaces traditional plaster casts or foam impressions, and it is sent to the laboratory alongside a clinical prescription detailing the patient's specific requirements, weight, and footwear type.

In the manufacturing phase, technicians use CAD software to design the orthotic shell based on the digital scan. The shell is then produced using binder jetting technology technology with a bio-plastic derived from castor oil chosen for its durability and flexibility. Once printed, the orthotic shell is hand-finished in the laboratory with the prescribed top covers and cushioning before being dispatched to the clinic.