Backed by research. Built for comfort. Designed in-house by our podiatry team.
At The Foot Clinics, we’ve adopted a new approach.
Our Next-Gen Orthotics are designed and 3D printed in-house using thermoplastic polyurethane (TPU) — a medical-grade material that provides improved comfort, performance, and clinical outcomes. This next-generation solution is engineered to reduce pressure, enhance shock absorption, and respond more naturally to foot movement.
If you’ve worn orthotics before and found them hard, uncomfortable, or difficult to break in – you’re not alone. Traditional orthotics have often relied on rigid plastics or dense foams that offer support but little in the way of comfort.
That’s exactly why we developed our Next-Gen Orthotics at The Foot Clinics.
Using a high-performance material called TPU (thermoplastic polyurethane) and custom 3D printing technology, these devices offer superior comfort, support, and fit.
So, What Makes These Orthotics “Next-Gen”?
Next-Gen Orthotics combine digital scanning, computer-aided design (CAD), and in-house 3D printing using TPU to deliver a highly individualised device.
Key features include:
High-resolution 3D scans of your foot and gait
Zoned design options to modify flexibility, firmness, and thickness in targeted regions
Rapid in-house manufacturing, reducing turnaround from weeks to days
Customisable geometry, allowing adjustments to arch support, heel cups, and forefoot control based on pathology
This process not only enhances fit but ensures biomechanical precision, making it suitable for a broad range of clinical presentations.
What is TPU — and Why Does It Matter?
Thermoplastic polyurethane (TPU) is a flexible, durable polymer commonly used in high-performance footwear, sports gear, and medical devices. Unlike EVA foam or hard polypropylene, TPU offers superior mechanical properties relevant to orthotic design.
Advantages of TPU orthotics include:
Enhanced shock absorption and energy return during loading
Greater tensile strength and shape retention over time
Improved comfort under variable loading conditions (e.g. walking, running, standing)
Heat and abrasion resistance, contributing to long-term wearability
These properties allow for a more adaptive and resilient device that maintains its function and structure even under high daily usage.
What the Research Suggests:
- A 2022 pilot study showed that air-filled TPU heel cushions significantly reduced plantar pressure in standing – ideal for people with heel pain or plantar fasciitis.
- A 2023 treadmill study comparing EVA and TPU orthotics found that material choice influenced foot and ankle mechanics, meaning TPU may affect how you move, not just how you feel.
- A 2020 review of insole materials found that polyurethane-based insoles reduced peak plantar pressures more effectively than using footwear alone.
These findings suggest TPU-based orthotics may offer improved comfort and function – especially when custom-designed using accurate scans and gait analysis.
Comfort, Engineered Into Every Step
Comfort plays a central role in orthotic adherence. Devices that are painful, bulky, or stiff are less likely to be worn — reducing their therapeutic value.
TPU’s unique mechanical profile allows us to deliver orthotics that:
Distribute plantar pressures more evenly across the foot
Minimise peak load at common pain sites like the heel and arch
Enhance step-to-step responsiveness, improving gait efficiency
Reduce the need for lengthy break-in periods, particularly in closed footwear
The result is a clinically effective device that supports movement while respecting individual comfort thresholds — particularly important in long workdays, sports participation, or chronic pain scenarios.
Who Benefits Most From Next-Gen Orthotics?
TPU orthotics are suitable for a wide range of conditions and patient types, but are particularly valuable for:
Individuals with plantar fasciitis, Achilles tendinopathy, or chronic heel pain
Active individuals seeking shock absorption and energy return
Patients with sensitive feet or past difficulty tolerating rigid orthotics
Workers exposed to prolonged standing or hard surfaces
These orthotics can also be tailored to specific footwear types — including athletic, work, or school shoes — making them versatile across daily activities.
Available at Wagga and Wodonga Clinics
Available at Wagga and Wodonga Clinics
If you’re experiencing foot pain, fatigue, or have struggled with orthotic comfort in the past, our Next-Gen Orthotics offer a forward-thinking solution. Designed by podiatrists, powered by technology, and built for real-life wear.
👉 Book your 3D orthotic assessment
👉 Learn more about our Next-Gen Orthotics
Frequently Asked Questions
What are TPU orthotics?
TPU orthotics are custom foot devices manufactured using thermoplastic polyurethane. This material offers superior cushioning, durability, and pressure redistribution compared to traditional orthotic materials.
Are TPU orthotics effective for plantar fasciitis?
Yes. TPU orthotics can help reduce peak pressure under the heel and arch, a key factor in the management of plantar fasciitis. Their comfort profile also improves compliance, which is essential for long-term symptom relief.
How are TPU orthotics different from regular orthotics?
Unlike standard orthotics made from EVA or rigid plastic, TPU orthotics are 3D-printed with customisable zones of flexibility and firmness. This results in better fit, faster turnaround, and more patient-specific outcomes.