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.

Marking 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.

Royal College of Podiatry Conference 2023

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Discover Firefly’s biocentric, fully sustainable 3D printed orthoses at this year’s Royal College of Podiatry conference.

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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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FIREFLY AMBASSADOR SKI-TRIP 2022

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In March of this year, a group of podiatrists travelled to the rarified air of the French Alps to spend time together to explore how they practice, discuss the challenges they face and ultimately learn how they can expand their thinking on the profession of podiatry.

Some of the conversations that took place in and around our Alpine chalet and on the slopes were captured on camera!

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