Material Application Update

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Following a review of our material we have an important update regarding certain materials we supply for specific orthotic modifications.

1.5mm Poron will no longer be offered for the following applications:

  • Reverse Morton’s Extensions
  • Functional Hallux Limitus Accommodations
  • Lesion Accommodations

This decision is based on performance and durability concerns. 1.5mm Poron has proven to be too thin for these applications, leading to quicker material breakdown and reduced clinical effectiveness.

Recommended alternatives:

Reverse Morton’s Extensions & Lesion Accommodations:
We recommend 3mm Cushion Cork for its resilience and cushioning properties.
3mm Poron or EVA may also be used depending on your clinical preference.

Functional Hallux Limitus Accommodations:
We recommend using EVA, which offers greater durability and functional support.

Gel & Aerosorb no longer available as a material options:

Firefly no longer offer gel as a material. While gel was previously used in applications such as heel hole modifications, it has been shown not to hold up over time and frequently fails to deliver the desired clinical outcomes. As a result, we have removed gel from our available material options.

We will also be discontinuing Aerosorb as a material option. For cases where Aerosorb may have previously been selected, we recommend using SR Poron in 3mm thickness, which delivers reliable performance and longevity.

If you have any questions or would like to discuss the best material choices for your patients, our team is happy to assist.<

Bridging Clinical Insight with 3D Printing: HSE Site Visit

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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.

FUSION Plus – Coming Soon

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FUSION Plus: The All-in-One Digital Prescription Solution – Coming Soon!

Launching soon, FUSION Plus is Firefly Orthoses’ advanced iOS app that streamlines the orthotic prescription process for podiatrists. It enables clinicians to capture patient foot anatomy and submit custom orthotic prescriptions—all within a single platform.

Unlike traditional methods that require third-party scanners, FUSION Plus leverages Apple’s TrueDepth technology, built into compatible iPhones and iPads, to deliver high-precision 3D foot scans without needing external hardware. For podiatrists who use Structure’s external scanners, the app also fully supports mk. 1, mk. 2, Structure Pro, and Structure 3.

Key Features

✅ TrueDepth 3D Scanning – No Extra Hardware Required

Capture high-precision foot scans using Apple’s built-in TrueDepth camera.
No need for third-party scanners—just use a compatible iPhone or iPad Pro.
TrueDepth technology is available on:

iPhone models –

iPhone 12 and later.
iPad Pro models –

iPad Pro 13-inch (M4)
iPad Pro 12.9-inch (3rd to 6th generations)
iPad Pro 11-inch (M4)
iPad Pro 11-inch (1st to 4th generations)
✅ Comprehensive Structure Sensor Support

Compatible with all Structure scanning hardware, including:

Structure Sensor mk. 1
Structure Sensor mk. 2
Structure Pro
Structure Sensor 3
✅ Integrated Prescription Writing

Scan and prescribe within the same app, eliminating paperwork and extra steps.
✅ Seamless Digital Submission to Firefly

Submit scans and prescriptions instantly, speeding up order processing.
✅ Fast & Efficient Workflow

Reduce clinical admin time and streamline patient assessments.
Why Choose FUSION Plus?

Whether using Apple’s TrueDepth technology or Structure’s scanning hardware, FUSION Plus offers unmatched convenience, speed, and accuracy, allowing podiatrists to go fully digital with ease.

FUSION is now compatible with Structure 3

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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.

Marking the Malleoli for Richie Brace

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The Importance of Marking the Malleoli for Richie Braces

Ensuring a precise fit for orthotic devices like the Richie Brace is crucial for both comfort and functionality. A key step in achieving this perfect fit is marking the apex of the medial and lateral malleoli. This simple yet effective practice can make a significant difference in the outcome for patients.

Why Marking Matters

Marking the malleoli helps eliminate guesswork during the fabrication process. When the apex of these bony prominences is indicated, it guides Firefly’s design team in accurately aligning the brace to your patient’s anatomy. This ensures the brace provides the intended support and correction, reducing the likelihood of discomfort or the need for adjustments.

How to Mark the Malleoli

Whether you’re using traditional casting methods or digital scanning technology, marking the malleoli is straightforward. For traditional casting, a felt-tip marker or dark pen can be used to highlight these areas on the cast. This visible mark guides the lab technicians in their work, ensuring they have precise reference points.

For podiatrists using Firefly’s scanning app FUSION, the malleoli should be identified before scanning by placing a material such as felt on the medial and lateral malleoli. These two exaggerated locations are then easily identified in the final scan file. This digital precision translates to a better-fitting orthotic device.

Prone or Supine Position?

When it comes to positioning the patient for marking the malleoli, both prone and supine positions can be effective. The choice depends on the practitioner/patient’s preference and the specific requirements of the scan or cast. The key is to ensure the malleoli are clearly marked and easily visible in the chosen position.

Support and Resources

At Firefly, we are dedicated to supporting practitioners in delivering the best care to their patients. Whether you need assistance with casting, scanning, or selecting the right Richie Brace solution, we are here to help. Our comprehensive range of resources includes detailed guides, expert consultations, and access to the latest advancements in orthotic technology.

Explore our full range of orthotic solutions, including Richie Braces, and discover how precise marking and expert craftsmanship can enhance patient outcomes.

Firefly Summer Webinar Series

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Firefly’s Summer Webinar Series sees some of the podiatry profession’s leading figures present practical and actionable foot and ankle focused CPD. Jump in to watch Dr. Tim Kilmartin, Dr. Doug Richie and Ms Zoe Wilson present on a range of podiatric MSK related topics.

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Ask Firefly: Answers to frequently asked questions on prescribing custom foot orthoses

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Watch our series of short videos that answer some frequently asked questions about the prescription of custom made foot orthoses.

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AN INTRODUCTION TO PRESCRIBING THE RICHIE BRACE | ZW ACADEMY.

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Learn from experts in the field of complex foot and ankle pathologies and the use of the Richie Brace modality at ZW Academy’s An Introduction to prescribing the Richie Brace course.

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10th Podiatric Sports Medicine Conference

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The Firefly Orthoses team will be attending the 10th Podiatric Sports Medicine Conference in Glasgow across the 8th and 9th of December 2022.

The conference is in collaboration and association with the British Association of Sports and Exercise Medicine (BASEM), the Royal College of Podiatry and the Royal College of Physicians and Surgeons of Glasgow hosted by Aesculap Academia.

Firefly will have a full range of custom made foot orthoses on stand number 7 at the conference.

This year also marks the 10th Anniversary of Podiatric Sports Medicine with the foundation stone laid by Professor Nat Padhiar after the London 2012 Olympic and Paralympic Games. To celebrate, a gala dinner will be held on the Thursday evening, which Firefly will be attend.

NEW OFFLOADING DEVICES

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We have re-designed our specialised device range of custom made foot orthoses, given them the new title of offloading devices and published an updated order form that is designed with the diabetic and rheumatoid arthritic patient in mind.

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