The Clinical Demand Behind Orthotics for Flat Feet Manufacturer at Scale
Pes planus - commonly known as flat feet - is one of the most frequently presenting biomechanical conditions across podiatry, pedorthics, physiotherapy and orthotics and prosthetics (O&P) clinics throughout Greater Sydney and beyond. For clinicians managing high patient volumes, the ability to source orthotics for flat feet from a manufacturer consistently, to clinical specifications, and in scalable quantities is a clinical necessity.
OrthoGenix is a Sydney-based, Australian-owned manufacturer and B2B supplier of custom orthotic solutions. We supply podiatrists, pedorthists, physiotherapists and orthotists across Australia and internationally, providing a reliable orthotics lab manufacturing service built for clinical workflow and volume.
A Manufacturing Process Built Around Each Patient
Every OrthoGenix custom orthotic begins with the patient's foot data. Clinicians submit 3D scan files, measurements and relevant documentation through our website. Our CAD design team then digitally designs the device to the patient's specific requirements. Once the design is confirmed, the device moves into production.
Using advanced 3D printing technology and 3D foot scanning, OrthoGenix captures precise data on foot structure and anatomy - ensuring each orthotic is tailored to the individual patient's foot shape and biomechanics. Pressure-mapping identifies high-stress areas, allowing devices to be designed to alleviate pressure at the points that matter most clinically.
Our team of certified pedorthists and O&P specialists oversees production, and our dedicated production team will liaise with the prescribing clinician where any clarification is needed during the process. The overall timeframe for custom orders is approximately 4 weeks.
Custom Orthotic Production Process at OrthoGenix
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Technologies Used in Modern Orthotics Production
OrthoGenix uses 3D printed orthotics manufacturing as a core production method. State-of-the-art 3D printing allows for geometry that traditional milling cannot replicate - precise arch contours, variable density zones and patient-specific shell thickness. Combined with CAD/CAM orthotics production, our foot scan to orthotic production workflow eliminates manual interpretation errors and significantly reduces the margin for clinical misfit.
Materials are selected according to clinical load and intended use:
EVA (Ethylene Vinyl Acetate) - preferred for its shock absorption and lightweight properties, particularly suited to paediatric flat foot presentations and lower-load applications
TPU (Thermoplastic Polyurethane) - used where greater rigidity and durability are required, such as adult weight-bearing orthotics or sport and occupational applications
PORON - used as a top cover and cushioning layer for pressure distribution and patient comfort
Materials used in orthotics manufacturing are matched to the patient's condition, body weight, activity level and footwear type - all determined by the clinical data your practice submits.
Funding Pathways Available to Your Patients
OrthoGenix-manufactured orthotics for flat feet may be eligible under a range of schemes, which your practice can help patients navigate:
- Medicare (EPC/CDM plans) for eligible chronic condition management patients
- Enable NSW for people with disability requiring assistive devices
- Workers' Compensation for work-related musculoskeletal presentations
- CTP Insurance for motor accident-related injuries affecting gait and foot function
- Home Care Packages for eligible aged care recipients requiring mobility support
- Private Health Insurance subject to individual policy extras coverage
We recommend that clinicians confirm eligibility directly with the relevant scheme provider when prescribing.
Ordering Through OrthoGenix
Clinicians order custom orthotics directly through the OrthoGenix website or OG scan app. The process is straightforward: visit the custom orthotics orders page or scan in our OGscan app, select your requirements, and upload the necessary documents - including 3D scans,Foam Impression box, foot measurements and any relevant clinical notes. Once submitted, our team reviews the order and provides confirmation.
For prefabricated orthotic and insole options, orders are placed directly through the site. In-stock items are dispatched the following business day. Where items require sourcing, the expected timeframe is approximately 4-6 weeks.
To access the full ordering platform, clinicians complete a simple 3-step partner registration: submit the partnership form, await our response, and receive confirmation. Partner clinics receive login credentials giving them access to the full product range and order management.
"Our goal is to revolutionise comfort and mobility through superior products - ensuring that everyone can move freely and confidently, thanks to our expertly designed and meticulously crafted solutions"
- Dr. Sayed Ahmed, PhD (Pedorthics) - Founder, OrthoGenix
Orders are fulfilled and distributed nationally across Australia and to clinical partners internationally, including New Zealand, Europe, the Middle East, Asia, Canada and the USA.
Ready to Supply Your Patients With Precision Orthotics?
OrthoGenix offers clinically rigorous orthotic manufacturing to a diverse range of foot and movement specialists worldwide, including podiatrists, pedorthists, physiotherapists, orthotists, and prosthetists. Each orthotic is precisely built to individual patient specifications for effective foot condition management, utilising certified pedorthists, advanced 3D printing, and CAD technology.