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Technology, Materials & Quality

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HOW IT WORKS

Technology, Materials & Quality

Custom 3D printed orthotics. An innovative digital rehab platform. Structured return to activity pathways.

Each component of the MM Podiatry system, chosen for reliability, consistency and clinical coherence.

Bespoke 3D printed orthotics: precision manufactured from your prescription.
How are 3D Printed Orthotics Manufactured?

Every orthotic shell is built layer by layer from a digital file of your prescription, giving precise control over thickness, stiffness, and geometry, with excellent repeatability between pairs.

The result reflects your prescription rather than a generic template. Every pair from the same file is identical. Adjustments and repeats are made at file level and reprinted precisely, with no variation, no guesswork, and a clear digital record of every device manufactured.

What 3D Printed Orthotic Materials are Used?

Shell material: TPU in different densities, polypropylene (PP) and carbon fibre options for higher stiffness requirements.

Top covers

The top cover is prescribed to match the clinical requirement, for example:

  • PORON — highly resilient shock attenuation through repeated loading cycles. For high-activity patients and sport.
  • PLASTAZOTE — moulds closely to foot contours and distributes load over a larger surface area. For diabetic, high-risk, or offloading presentations.
  • LUNATEC MOTION — reduces shear forces at the foot-orthotic interface. For presentations where shear is the primary concern.

Combinations are available for complex presentations. We can advise on appropriate specifications.

What Quality and Compliance Standards Apply?
  • Filament: UNEEN 11865:2002, EU 10/2011, USP regulations for topical use.
  • Filament supplier: ISO 9001 and ISO 13485 certified.
  • Top cover material: ISO 9001 certified.
  • Every device is checked before dispatch.
  • Clear digital record maintained for every pair manufactured.
Orthotic in shoe
HOW IT WORKS

RehabHub 3D: An Innovative Digital Rehabilitation Platform

RehabHub 3D is more than a consumer fitness app. It is an exercise prescription software with the tools to prescribe, monitor and progress structured rehabilitation in a busy practice, and the compliance standards expected of a clinical platform.

What Does the RehabHub 3D Platform Offer?
  • 3D exercise demonstrations that are viewable from any angle, on any device, so patients know exactly how to perform each exercise.
  • Real-time compliance tracking — clinicians see what patients have completed between appointments.
  • Multi-week scheduling with built-in progressions. Programmes advance automatically, matched to the patient's plan.
  • One-click templates — pre-built protocols for plantar heel pain, Achilles tendinopathy, tibialis posterior dysfunction, and more.
  • Patient video recording. You record the exercise in the clinic and attach it to the patient's plan for personal reference at home.
What Compliance and Technical Standards Apply?
  • GDPR-compliant. Patient data stored on London-based servers.
  • Available on iOS, Android, any web browser, and AR/VR headsets.
  • No limits on patient capacity.
  • 30-day free trial — no card required, cancel anytime.
  • MM Podiatry holds exclusive rights to offer RehabHub 3D to clinicians in the UK.
See RehabHub 3D
Finishing orthotics
HOW IT WORKS

Walkactive and Streek: Structured Return-to-activity Programmes, Delivered Digitally

MM Podiatry return-to-activity programmes are delivered through our partners WalkActive and Streek — both established, digitally delivered programmes that clinicians can recommend to patients via a referral link or QR code.

WalkActive — walking and everyday function programme

Accessed through a digital platform and app. Multiple programmes matched to patient goals and activity level. Built around gait modification techniques that are broadly supported by the evidence. Clinicians guide patients to the appropriate programme; WalkActive manages the progression.

Streek — running programme
Accessed through a digital platform and app. Plans available across all levels — from new runners through to competitive athletes — covering frequency, duration, intensity, nutrition, mobility, and recovery.

3D Printed Orthotics: Materials & Technology

More information about our 3D printed custom orthotic materials and technology
TPU shells are designed for sustained clinical use. Durability depends on patient activity level, footwear, and loading patterns, as with any orthotic material. Top covers and cushioning layers wear at different rates and can be replaced without replacing the shell. Manufacturing or material defects within 30 days of receipt are remade at no cost.

Yes. MM Podiatry accepts digital scans alongside foam impression boxes and slipper casts.

Every device is checked against the prescription specification before dispatch. A clear digital record is maintained for every pair manufactured. If a device does not meet the clinical fit standard despite reasonable adjustment within 60 days of receipt, we cover one redesign and reprint at no extra cost.
Minor adjustments — covers, pads, wedges — can be made chairside. If the shell needs changing, we will update the design file and reprint. A 60-day clinical fit guarantee covers one redesign and reprint if needed.

Yes — from the same digital file, without new casts, if the foot has not changed significantly.

TESTIMONIAL

What Our Partners Say

As a busy private podiatry practice, bespoke foot orthoses sit at the core of our MSK service, so we’re very selective about who we work with. Since moving to this MM Podiatry, the consistency and quality of the 3D‑printed orthotics have been excellent, reliably reducing pathological tissue loading and giving us the stable mechanical foundation we need for rehab.

The integrated RehabHub 3D platform is a genuine value‑add for our patients. It allows us to progress tissue loading in a structured, evidence‑informed way and gives patients clear, accessible plans that complement their orthoses instead of just a generic exercise sheet. We also use it for prehab and minor niggles between appointments, which has noticeably improved engagement and adherence.

Together, the orthotics and digital rehab pathways have made our MSK care feel more joined‑up and professional. We spend less time on admin and workarounds and more time delivering a complete journey from overload and pain to restored function and confidence.

Marie Young, Senior Podiatrist & Practice Owner
Allerton Road Foot Clinic, Liverpool

As a relatively new podiatry practice, I’ll admit I lacked confidence when it came to prescribing bespoke orthoses. I knew some of my patients needed more than off‑the‑shelf devices, but the sheer number of design choices, variables and suppliers made me nervous about getting it wrong. Partnering with MM Podiatry has completely changed that.

The prescription process is clear and guided, and the support behind it has been invaluable. I feel like I have an expert ‘in my corner’ helping translate my clinical findings into high‑quality, 3D‑printed orthotics that actually do what I need them to do.  My confidence has grown and so has my willingness to take on more complex MSK patients.

Having RehabHub 3D alongside the orthoses has been a big bonus. It gives me ready‑made, professional rehab prescriptions that I can quickly tailor to each patient, instead of piecing exercises together from scratch. Patients see it as a premium, joined‑up service rather than just “getting some insoles”, and that’s helped me grow the MSK side of the business much faster than I expected.

Working with MM Podiatry has allowed me to offer a level of orthotic and rehab care that feels more like an established MSK clinic than a start‑up, and it’s given me the confidence to build my reputation in this area.

Simon Barnes, Podiatrist & Owner
Newton Podiatry