Insolace® 3D Print Farm
3D Printed Orthotic Insole Manufacturing for Clinics & Trade Partners
Tailored Digital Orthotic Solutions Built Around Your Needs
The Insolace® 3D Print Farm is the specialist additive manufacturing division of ACE Feet In Motion, delivering affordable, high-quality 3D printed orthotic insoles in the UK for podiatrists, orthotists, MSK clinicians, NHS suppliers and private orthotic brands.
Operating from our solar-powered Cardiff facility, Insolace® runs over 30 industrial-grade 3D printers, enabling carbon-neutral, high-precision orthotic production with faster and more predictable lead times than traditional orthotic manufacturing.
As proud members of the Made in Britain association, we reinforce our commitment to UK-based quality, responsible production and secure supply chains.
UK Partnership With LutraCAD
Through our exclusive partnership with LutraCAD – the Dutch pioneers in orthotic CADCAM technology, the Insolace® 3D Print Farm at ACE Feet in Motion can now provide flexible, fully integrated digital workflows centred around:
SCAN | DESIGN | PRINT | FINISH
Whether you require fully outsourced orthotic manufacturing, a hybrid CAD support model or a complete in-house digital setup, we tailor a cost-effective solution aligned to your clinical, operational and commercial goals.
Looking for a new orthotic manufacturing partner? Contact us today.
Affordable Precision Manufacturing
Traditional orthotic manufacturing can be labour-intensive, material-heavy and time-consuming. Additive manufacturing transforms this process. By streamlining production, eliminating unnecessary waste and reducing manual intervention, Insolace® delivers precision-controlled orthoses at scale, which enables us to maintain affordability for our trade customers.
For our trade partners, this means:
- • Improved margins
- • Digitally repeatable insoles
- • Reliable, predictable lead times
- • Sustainable UK-based supply
We believe advanced orthotic manufacturing should not come at a premium price point. Insolace® combines performance, efficiency and value within one scalable production model.
Why Choose Additive Insoles?
Traditional manufacture relies on layering, milling or vacuum forming and secondary bonding, all processes that can introduce variability and extended lead times.
Additive orthotic manufacturing replaces this with a fully digital, CADCAM-driven workflow designed for accuracy and structural integrity.
At Insolace®, every orthosis is digitally engineered to integrate prescription features, structural control and density variations directly into the device build. This removes unnecessary production stages, reduces human variability and ensures highly accurate, consistent results across every production run.
Additive orthoses deliver functionality comparable to and often exceeding traditionally manufactured devices. Complex geometries, integrated postings and multi-density structures are engineered directly into the orthosis, improving strength, repeatability and long-term durability.
Benefits Of Additive Manufacturing
Compared to traditional manufacture, Insolace® additive production offers:
- • Greater manufacturing accuracy and consistency
- • Digitally repeatable, quality-controlled output
- • Comparable or enhanced functional performance
- • Shorter and more predictable lead times
- • Lightweight yet durable material platforms
- • Reduced waste through additive processes
- • Carbon-neutral production within our UK facility
For trade partners, this means better reliability, improved supply control and long-term operational confidence.
Our Advanced Additive Orthotic Materials
Insolace® manufactures three digitally engineered orthotic material platforms using specialist MDR-compliant materials, clinically trialled and tested within real-world settings. Each material is developed for mechanical performance, structural stability and prescription flexibility, all produced using advanced CADCAM design and precision additive manufacturing.
Nimbus®
EVA-Like Multi-Density TPU
Nimbus® is a specialist MDR-compliant soft TPU engineered to replicate and enhance the characteristics of traditional EVA. Multi-density structures and prescription features are printed directly into the orthosis, creating a fully integrated device with excellent patient compliance.
Flexible, lightweight, carbon neutral and fully recyclable, Nimbus® combines comfort and performance within a sustainable digital manufacturing model. Top covers can be applied where required.
Request a sampleTitanis®
Polypropylene-Like Semi-Rigid Shell
Titanis® is an MDR-compliant semi-rigid material platform designed to mirror the functional control of traditional polypropylene devices. Manufactured using high-precision flat-bed additive systems, it delivers structural consistency, digital repeatability and long-term durability without vacuum-forming variability.
Lightweight, recyclable and waste-free in production, Titanis® provides a modern alternative to conventional plastic orthoses. Finished with a range of top covers as required.
Request a sampleNylon12 (PA/12)
Carbon-Like Rigid Shell
Produced using advanced Multi Jet Fusion (MJF) technology, Nylon PA12 delivers rigid, low-profile shells comparable to carbon composite devices. Ideal for high-control prescriptions and slim footwear applications, it offers exceptional strength-to-weight performance and dimensional accuracy across every build cycle.
Finished with top covers to suit your specification.
Request a sample
We Offer Flexible Workflow Models to Suit Your Business
Get in touchFully Outsourced Manufacturing
Send us your digital scan or impression and prescription. Our team designs, prints and finishes the orthosis at the Insolace® 3D Print Farm, delivering ready-to-dispense devices that can promote your own brand if desired.
Hybrid Workflow
Capture your own scans or impressions and operate your own 3D printer (supplied by us if required). Our experienced CAD operatives complete the digital design and transmit secure, print-ready files directly to your system for you to print.
Fully In-House Digital Solution
Through our LutraCAD partnership, we supply scanning/capture systems, pressure plate analysis systems, orthotic CAD software, industrial-grade printers and approved additive materials, allowing you to own the entire digital workflow and maximise margin while scaling your own production.
Why Partner With Us?
Insolace® is more than a 3D print farm, it is a long-term digital orthotic manufacturing partner.
Partnering with us provides direct access to a multidisciplinary support team including an experienced MSK Podiatrist, specialist CAD operatives, an Orthotic Technician, a software engineer and a dedicated account handler.
This ensures clinical oversight, technical accuracy and responsive commercial support throughout every stage of your workflow
SCAN | DESIGN | PRINT | FINISH
With over 30 industrial printers operating from our solar-powered UK facility, clinically tested MDR-compliant materials and more than 25 years of orthotic manufacturing expertise behind the ACE Feet In Motion brand powered by LutraCAD’s software and technologies, Insolace® delivers: Competitive trade pricing, Improved lead times, Scalable digital workflows, Reliable UK-based supply.
If you are looking to strengthen your orthotic supply with a trusted UK 3D printed orthotic manufacturer, Insolace® is ready to support your next stage of growth.
The ordering process
Get in touchStep 1.
Set Up Account
For all new customers we advise getting in touch with our trade accounts team (trade@feetinmotion.co.uk) where they will be able to provide all of the relevant information including our latest price list, impression boxes and an invite to our manufacturing facility to meet the team (not compulsory).
Step 2.
Download Our Digital Prescription Forms
Download our relevant digital prescription order form below and complete as required for your patient’s needs.
> Traditional Modular Insole Prescription Form
> Traditional Custom Insole Prescription Form
> Bespoke 3D Printed Insole Prescription Form
Step 3.
Send Patient Cast/Impression/3D Scan (Bespoke)
Once we have received your patient’s foot casts, impression box or digital scans we can then start the manufacturing process.
Step 4.
Send Patient Prescription (Modular & Bespoke)
Whether you opt for modular or bespoke functional foot orthoses we will require our relevant prescription form to be completed. Preferably, this can then be emailed to us with scans or printed and posted with accompanying impressions or casts.
Step 5.
Manufacture
Once we have received the relevant information sit back and relax. Once the insoles have been manufactured we will post the devices to the desired location.
Enquire Today
Speak to our dedicated trade team to discuss outsourced manufacturing, hybrid CAD support or full in-house digital workflow implementation. Let’s build your SCAN | DESIGN | PRINT | FINISH solution as you wish!
Contact information
Official partners
Get in touch
Quality certification – why is this important?
As manufacturers of custom made orthotic medical devices we must have the relevant quality certification. This means going through regular audits to make sure our facility, materials and staff all fit standard requirements. We are currently up to date and certified with ISO 13485:2016 which is seen as the international gold standard for quality in the medical device industry. As manufacturers of medical devices we are also registered with the MHRA.
As a healthcare practitioner who prescribers insoles it is up to YOU to check that your orthotic manufacturer has this certification and registration.