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In May 2025, we welcomed 17 Irish podiatrists to our state-of-the-art 3D printing facility in County Sligo for an immersive clinical education event, led by Firefly Orthoses CEO & Founder Martin McGeough.

With over 35 years of experience in podiatric biomechanics and musculoskeletal medicine, Martin guided attendees through the evolution of orthotic theory—from the Root model and tissue stress theory to sagittal plane facilitation—emphasizing how these paradigms are interconnected, not isolated.

A live case study demonstrated this approach in action:

Patient: Siobhan, presenting with right 1st MTPJ pain and suspected early-stage Adult Acquired Flatfoot.
Assessment: Mild flexible pes planus, tibialis posterior overload, ankle equinus, posterior chain weakness.
Solution: A tailored combination of 3D-printed orthotic devices (sport and dress options) designed using the Firefly Fusion App and Structure Sensor technology.

The event also highlighted the critical role of rehabilitation and strength training, including targeted exercises for the posterior chain and soleus, and appropriate footwear recommendations.

At Firefly, we’re committed to integrating clinical expertise with cutting-edge digital design and additive manufacturing to create custom devices that empower podiatrists and improve patient outcomes.

Firefly is delighted to welcome the podiatry profession to our HQ in Sligo. If you’re interested in scheduling a visit, please don’t hesitate to reach out.

Thank you to all who joined us—together, we’re shaping the future of foot orthoses.

We are delighted to announce that our  FUSION app is now compatible with the Structure 3 scanner, as well as the previous Structure scanners, Mk.1 and the Mk.2.

Firefly’s Digital Workflow: From Scanning to Custom Manufacturing

The Structure 3 scanner provides podiatrists with the ability to capture high-accuracy (up to 1mm) 3D scans of patients’ feet. These scans are then sent directly from the FUSION app to Firefly, forming the basis of the design files for each orthotic. This digital-first approach means that every step—from patient assessment to orthotic fabrication—is powered by precision technology.

Step-by-Step: Firefly’s Digital Workflow

1. Capture the 3D Scan Using the Structure 3 scanner and the FUSION app, podiatrists create detailed digital models of patients’ feet. The 1mm accuracy of the Structure 3 ensures each scan captures critical anatomical details, helping Firefly produce orthoses that fit comfortably and function effectively.

2. Submit the Digital File With the FUSION app, scans and prescription details are easily submitted to Firefly via iPad. This streamlined process reduces the need for manual input, improving efficiency and minimising the risk of errors in the prescription process.

3. Design of Custom Orthoses Once received, Firefly’s design team utilises the digital scan files and prescriptions for the creation of each custom orthotic. This digital data-driven approach enhances the precision of the design process and allows for more customisation based on the podiatrist’s specifications and the patient’s needs.

4. 3D Printing Firefly employs state-of-the-art 3D printing technology to fabricate each custom orthotic. This method ensures that the orthoses meet Firefly’s high quality, durability, and fit standards.

Benefits of Firefly’s Digital Workflow

The shift to a fully digital workflow offers a range of benefits for podiatrists, their patients, and the custom orthotic industry:

• Increased Precision Digital scans and 3D printing allow for orthoses with exceptional fit and functionality, paving the way for excellent patient satisfaction.
• Efficiency Gains The digital workflow reduces time-consuming manual steps (foam boxes and plaster of Paris), helping podiatrists improve their practice efficiency and focus more on patient care.
• Seamless Data Transfer Using FUSION and Structure 3, podiatrists can capture, process, and submit scans effortlessly, reducing the chance of errors and ensuring a seamless experience for both clinician and patient.
• Quality Assurance With each orthotic based on a digitally optimised design, podiatrists can be confident in the quality and consistency of the product delivered.

Supporting Podiatrists with Advanced Technology

Firefly’s end-to-end digital workflow with the FUSION app and Structure 3 offers podiatrists a complete solution for custom orthotic prescriptions, from scan capture to design and 3D printing. This innovative approach is part of Firefly’s commitment to providing podiatrists with technology that advances patient care and optimises clinical efficiency.