Introducing the Insolace® 3D Print Farm

Affordable, High-Quality UK 3D-Printed Orthotic Insoles

For more than 25 years, ACE Feet in Motion has been one of the best kept secrets in Wales, manufacturing orthotic insoles at scale for healthcare providers, elite sport and major organisations across the UK and beyond. From Emirates and the Ministry of Defence to the NHS, Under Armour (EU), the Premier League, the Welsh Rugby Union, Ford, Royal Mail and Arriva Trains, our manufacturing capability has been developed through decades of private-label and specialist trade partnerships.

The launch of the Insolace® 3D Print Farm marks the natural evolution of that experience, integrating advanced additive manufacturing into an established UK orthotic production environment. Insolace® enables us to deliver high-quality, UK-manufactured 3D printed orthotic insoles through a digitally controlled workflow built for modern clinical and commercial demands.

Operating from our solar-powered purpose built Cardiff facility, Insolace® currently runs more than 30 industrial-grade 3D printers, combining precision manufacturing with scalable efficiency. The result is repeatable, high-quality production at a commercially sustainable price point.

Full details of the Insolace® 3D Print Farm can be found here:
https://www.feetinmotion.co.uk/services/corporate-services/insolace-3d-print-farm/

Flexible Digital Workflow Options

We offer three flexible digital workflow models, fully outsourced manufacturing, a hybrid CAD-supported pathway, and a complete in-house digital solution. This allows us to tailor implementation to the needs of each clinic or organisation, whether beginning their digital journey or expanding existing capability.

Supporting these workflows is a multidisciplinary team comprising MSK Podiatrists, specialist CAD operatives, software engineers and a dedicated trade account handler. This ensures clinical oversight, technical accuracy and consistent commercial support throughout every stage of the SCAN / DESIGN / PRINT / FINISH process.

Through our exclusive UK partnership with LutraCAD, we can now supply capture and scanning software, orthotic CAD platforms, foot scanners, pressure plate systems, industrial 3D printers and approved additive materials, supporting each workflow model from scan to finished orthosis.

If you’d like to discuss your workflow requirements for a tailored solution – get in touch here

A Considered Move into Digital Orthotics

As 3D printing gained traction within the orthotics sector, it became clear that many systems struggled to deliver consistent quality at clinical scale. Over two years, Paul and Tom Cooper assessed emerging technologies globally, focusing on material performance, repeatability, design flexibility and commercial viability.

This search led to LutraCAD in the Netherlands. What stood out was the strength of the complete digital ecosystem, intuitive CAD software, advanced design tools, MDR-compliant materials and scalable hardware without prohibitive capital cost.

You can learn more about LutraCAD here: https://www.lutracad.com/

Paul Cooper, Group CEO and Co-Owner at Ace Orthotics Ltd, comments:

“Our mission has always been to deliver the highest-quality orthotic solutions at the best possible value, and LutraCAD enables us to do exactly that. Their open, accessible and cost-effective digital ecosystem provides the precision and repeatability required for modern clinical manufacturing without the barriers that have restricted digital adoption in the past.

We are delighted to integrate these technologies into the Insolace® 3D Print Farm and to make them available to hospitals, podiatry clinics and MSK professionals across the UK and Ireland.”

Making 3D-Printed Orthotics Work Clinically

For many clinicians, early 3D printed orthotics failed to balance material quality with affordability. Successful implementation required a system that was repeatable, scalable and cost-effective, without compromising patient tolerance.

Tom Cooper, MSK Podiatrist and Co-Owner, explains:

“3D-printed insoles have been impossible to ignore in recent years, yet I had never found a solution that truly worked for both myself as a clinician and for our clinic.

As both a practitioner and someone overseeing our manufacturing facility, I needed a system that was repeatable, scalable and cost-effective. Limitations in material quality and the high cost of printers made implementation difficult.

Today, that has changed. Through our partnership with LutraCAD and the introduction of additive materials Nimbus, Titanis and Nylon 12, combined with intuitive design software and affordable printing systems, I am now confident that 3D printing is not just viable, but the future of custom orthotic manufacturing.”

Innovative Additive Materials

Insolace® uses three MDR-compliant additive materials designed for structural consistency and prescription flexibility.

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Nimbus®, an EVA-like multi-density TPU, integrates prescription features directly into the digital build for improved comfort and repeatability.

Titanis®, a polypropylene-like semi-rigid shell, offers reliable structural control with enhanced dimensional consistency.

Nylon12 (PA12) a rigid carbon-like shell produced using Multi Jet Fusion technology, delivers high strength-to-weight performance for demanding prescriptions.

By embedding prescription design directly into the additive process, our UK 3D printed orthotic insoles achieve improved consistency, reduced variability and controlled production efficiency, allowing us to maintain both quality and affordability.

Are you considering outsourcing your manufacturing or looking for a new print partner to service your 3D printed insole requirements? – Get in touch here

Manufactured in Britain

Insolace® operates from our Cardiff facility as proud members of the Made in Britain and Manufacturing Wales associations.

Manufacturing within the UK shortens supply chains, improves reliability and reduces lead times, providing greater predictability in an environment where global disruption cannot impact supply.

The Insolace® 3D Print Farm represents practical progression, combining more than 25 years of orthotic manufacturing expertise at ACE Feet In Motion, with affordable, digitally precise, and scalable 3D printing solutions.

To learn more about the Insolace® 3D Print Farm and the flexible workflows we can offer, please visit: https://www.feetinmotion.co.uk/services/corporate-services/insolace-3d-print-farm/

For further information or to arrange a discussion with our dedicated trade team, please email trade@feetinmotion.co.uk.