OrthoGenix Blog / Precision-fabricated custom foot orthotics, supplied to Australian clinicians and allied health practices

Precision-fabricated custom foot orthotics,
supplied to Australian clinicians and allied health practices

Medically reviewed by Dr. Sayed Ahmed (PhD, Pedorthics) — OrthoGenix Clinical Advisory

OrthoGenix is a Sydney-based, Australian-owned manufacturer and distributor, supplying podiatrists, pedorthists, physios and orthotists with prescription-grade devices for the full range of foot and lower limb presentations. Unlike prefabricated insoles, every element of a custom orthotic - from arch support geometry and heel cup depth to shape and material selection - is determined by clinical assessment and gait analysis findings, ensuring each device is fabricated to the specific measurements and clinical requirements of the individual patient.

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Presentations that respond well to custom foot orthotics

Custom foot orthotics are appropriate across a wide range of podiatry solutions and musculoskeletal presentations. Clinicians regularly prescribe them for:

Plantar fasciitis

Custom orthotics for plantar fasciitis offload the insertion of the plantar fascia through targeted arch support and heel cushioning, addressing the mechanical load that drives the condition. Prefabricated devices rarely provide the precision required for chronic or refractory cases.

Flat feet

Custom orthotics for flat feet correct rearfoot position, improve heel alignment and redistribute pressure across the plantar surface. In paediatric presentations, early orthotic intervention can support normal foot development.

Diabetic foot

Pressure distribution management is critical in diabetic patients at risk of ulceration. Custom insoles Australia-wide are fabricated by OrthoGenix to accommodate diabetic foot requirements, including offloading of vulnerable bony prominences.

Heel pain, forefoot pain and metatarsalgia

Orthopedic support through a custom device addresses the specific pressure concentration driving pain, rather than providing generalised cushioning.

Sports and high-activity presentations

Patients with high mechanical demand require devices that can withstand repetitive load while maintaining corrective function.

Post-surgical rehabilitation

Following procedures affecting the foot or ankle, a custom orthotic supports appropriate load distribution during recovery.

The fabrication process behind a prescription foot orthotic

OrthoGenix produces custom made orthotics using both traditional casting methods and modern 3D printed custom orthotics technology. CAD/CAM fabrication from digital scans allows for precise, reproducible devices - particularly useful for clinics managing high patient volumes or requiring consistent results across repeat orders.

Material selection is matched to clinical need. EVA foams, polypropylene shells, carbon fibre reinforcement and a range of top-cover materials are used depending on the patient's diagnosis, weight and activity requirements. A custom orthotic for a diabetic patient looks very different from one prescribed for a competitive runner - and both look different from a paediatric device for flat feet.

Prescription foot orthotics from OrthoGenix are fabricated to the specifications submitted by the prescribing clinician. We work with the clinical data provided - whether cast, scan or detailed measurement - and produce devices that reflect the prescription accurately.

Bulk supply of custom foot orthotics for clinics and practices

OrthoGenix supplies custom foot orthotics to podiatry practices, physiotherapy clinics, orthotics departments and allied health groups across Australia and internationally. Our supply model is built around clinical workflow - orders are fulfilled to prescription specifications, with consistent turnaround times that support appointment scheduling and patient follow-up. Clinics managing high patient volumes benefit from our CAD/CAM fabrication, which delivers reproducible results across repeat orders and reduces variation between devices. Clinics requiring bespoke foot orthotics at volume are welcome to contact us to discuss their ordering requirements.

Private label custom insoles are also available for practices wishing to supply devices under their own clinic branding. Contact OrthoGenix directly to discuss private label options.

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Precision Orthotics for Every Presentation

Custom foot orthotics are the most precise intervention available for foot and lower limb biomechanical presentations. Whatever your case mix or volume, OrthoGenix has the fabrication capability and supply infrastructure to meet your demand. Contact us to discuss your requirements.

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Frequently Asked Questions

Are custom orthotics worth it?

For the right presentation, yes. Custom orthotics consistently outperform prefabricated devices in complex, chronic or high-load presentations. For mild or acute conditions, a prefabricated device may be appropriate as a first-line intervention. The clinical decision depends on diagnosis, patient history and response to previous treatment.

How do custom orthotics work?

Custom orthotics work by modifying the mechanical environment of the foot during weight-bearing activity. By correcting foot posture, redistributing plantar pressure, providing targeted arch support and improving heel alignment, they reduce the load on symptomatic structures and support more efficient foot biomechanics through the gait cycle.

Do custom orthotics or prefabricated insoles suit my patient better?

Prefabricated devices are appropriate where the presentation is mild, the foot morphology is close to standard and the clinical goal is general support rather than precise correction. Custom orthotics are indicated where the presentation is complex, chronic or has failed to respond to conservative measures, or where precise pressure distribution management is required - as in diabetic foot care.

How long do custom orthotics last?

This varies by material and patient activity level. Polypropylene shell orthotics typically last several years with appropriate care. Softer EVA devices wear more quickly under high activity. We recommend clinicians advise patients on expected device lifespan at the time of fitting and schedule review appointments accordingly.

What funding schemes cover custom foot orthotics in Australia?

Custom foot orthotics may be covered under NDIS, DVA, Enable NSW, workers' compensation, CTP insurance and Home Care Packages, depending on the patient's circumstances. Eligibility criteria and item coverage are subject to change, so clinicians should confirm current approval processes directly with the relevant funding body.

How much do custom foot orthotics cost in Australia?

OrthoGenix supplies custom foot orthotics to clinicians and practices.. Pricing for clinical supply is available on enquiry. The cost of custom orthotics to patients is set by the prescribing practice.

Are 3D printed custom orthotics as effective as traditionally fabricated devices?

3D printed custom orthotics offer excellent precision and reproducibility, and are increasingly used in clinical practice. Material properties differ from traditional EVA and polypropylene fabrication, and device selection should be matched to the clinical presentation. OrthoGenix can advise on appropriate fabrication methods for specific case types.