Orthotic Manufacture
Orthotic Manufacture for Healthcare Professionals
ACE Feet In Motion has over 25 years’ experience manufacturing functional foot orthoses. From our Cardiff-based solar powered facility, we produce high-quality prefabricated, modular and bespoke insoles for Podiatrists and other healthcare professionals across the UK and Ireland.
By combining advanced CADCAM technology with traditional precision milling and specialist additive manufacturing in our Insolace® 3D-Print-Farm, we ensure exceptional accuracy, repeatability, consistent quality and reliable lead times.
Trusted by leading organisations including the NHS, WRU, MOD, Emirates, Under Armour (EU), the Premier League and Ford, we manufacture orthoses that meet the highest clinical and performance standards.
Prefabricated Insoles
Our own-branded prefabricated (off-the-shelf) insole ranges – Junior FiMs® and Senior FiMs®, were designed, trialled and clinically tested within our UK private clinics and NHS settings before being released to the market. They are now available to purchase direct.
These ready-to-dispense devices allow immediate chairside application while providing reliable support for common foot pathologies. They can be easily adjusted in clinic through the addition of specialist postings where required.
Ideal as a first-line, cost-effective solution for straightforward cases, they complement our modular and bespoke orthotic solutions.
Customised Modular Insoles
Our adult modular range is available in low, medium and high density options, providing a versatile foundation from which to build your prescription.
With over 25 years of orthotic manufacturing expertise, we developed ModularFiMs® to bridge the gap between prefabricated and fully bespoke devices.
Each modular insole begins with a pre-manufactured shell set to an optimised foot position, which is then clinically customised by a trained Orthotic Technician. Prescriptions may include corrective postings, additional cushioning or targeted functional modifications based on assessment findings.
ModularFiMs® provide a clinically effective solution for a wide range of common foot and lower-limb pathologies, offering greater prescription flexibility than off-the-shelf devices while maintaining efficient production and dependable lead times.
Bespoke Insoles
Our bespoke insoles are manufactured to your patient’s exact foot shape and clinical prescription.
To produce a fully custom device, you will need to capture the foot using your preferred method typically a cast, impression box or 3D scan and submit this alongside a completed prescription form.
Using advanced CADCAM technologies, our orthotic technicians and designers digitally design each device to ensure accuracy, repeatability and clinical integrity. Production is carried out using high-precision CNC milling, vacuum forming or specialist 3D printing additive manufacturing techniques, depending on the specification and clinical requirements.
By combining technical expertise with modern manufacturing processes, we deliver high-quality, fully customised orthoses tailored precisely to your patient’s needs.
Traditional Options
Our traditional insole options offer a range of proven material choices to suit varying clinical requirements, levels of control and footwear considerations. Manufactured with precision and available in multiple densities and finishes, these devices provide reliable functional support while allowing flexibility in prescription and modification.
EVA
Our CADCAM-designed and manufactured EVA orthoses are a popular choice among the NHS and podiatrists nationwide.
Available in A18, A30, A40, A50, A70, A30/50 and A50/70 densities (samples available on request), this material offers excellent versatility across a wide range of clinical presentations.
EVA devices are associated with high patient compliance due to their comfort and adaptability. The base material is easily modifiable, providing extensive prescriptive flexibility to meet your clinical requirements. A range of finishes and posting options are available to suit your clinical prescription.
Polypropylene
Our polypropylene devices are vacuum formed to your patient’s rectified cast to ensure accuracy of fit. Durable, adaptable and well tolerated, they provide reliable functional control while maintaining patient comfort. A range of finishes and posting options are available to suit your clinical prescription.
Request a sampleCarbon Composite
Our most rigid and lowest-profile device, designed for maximum control where enhanced stability is required. Its slim construction makes it particularly suitable for lower-profile footwear without compromising structural integrity or performance. A range of finishes and posting options are available to suit your clinical prescription.
Request a sampleAdditive Options
Our additive insole options are designed using advanced CADCAM technology and manufactured at our dedicated Insolace® 3D-Print-Farm using specialist industrial 3D printing systems. This fully digital workflow enables precise integration of prescription features directly into the orthosis, ensuring exceptional accuracy, repeatability and design consistency. Additive manufacturing allows complex geometries, multi-density structures and fully integrated posting without secondary bonding or material waste. The process reduces production variability, improves turnaround predictability and supports on-demand manufacturing. The result is a lightweight, strong and durable orthosis produced with carbon-neutral processes, zero offcut waste and fully recyclable material options all without compromising clinical performance.
Nimbus®
EVA-Like Multi-Density TPU
Manufactured using specialist MDR-compliant soft, flexible TPU, our Nimbus® filament replicates the performance characteristics of traditional EVA while utilising advanced additive manufacturing.
Produced using specialist carpet printers, each device benefits from multi-density printing, with posts and prescription features built directly into the orthosis during print. This creates a lightweight, fully integrated device with exceptional accuracy and 100% repeatability.
The material is carbon neutral and recyclable, offering a more sustainable alternative without compromising clinical performance or durability. Prescription features can be digitally integrated into the device for accuracy and consistency and top covers can also be added if desired.
Titanis®
Polypropylene-Like Semi-Rigid Shell
Manufactured using specialist flat-bed printing systems, Titanis® filament is an MDR-compliant material designed to replicate the functional characteristics of polypropylene.
This semi-rigid shell delivers reliable structural control while benefiting from the precision and repeatability of advanced additive manufacturing. Prescription features can be digitally integrated into the device for accuracy and consistency and top covers can also be added if desired.
Titanis® devices are lightweight, exceptionally durable and 100% repeatable in production. The additive manufacturing process is carbon neutral, generates no material waste and produces a fully recyclable orthosis offering a sustainable alternative without compromising performance.
Nylon12 (PA/12)
Carbon-Like Rigid Shell
Produced using specialist Multi Jet Fusion (MJF) printing technology, Nylon PA12 delivers lightweight, low-profile shells with rigidity comparable to carbon composite devices.
This advanced additive manufacturing process enables precise, repeatable production while maintaining excellent structural strength and durability. The result is a strong, slim-line orthosis suited to cases requiring enhanced control without adding unnecessary bulk. Prescription features can be digitally integrated into the device for accuracy and consistency and top covers can also be added if desired.
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.
Trade Enquiries
If you have any questions or need further assistance, we’re here to help. Feel free to reach out through our contact form or give us a call. Our dedicated trade team is ready to support you with further information or any samples you may need.
Contact information
Official partners
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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.
