Orthotic manufacturing at the London Orthotic Consultancy

Since we opened in 2005, LOC has considerably expanded its in-house manufacturing capabilities and capacity.

Over the years we’ve recruited a group of technicians who are both highly skilled and very experienced. We’re now also bringing on our own younger recruits; each staff member has a specific specialised skill that contributes to the quality of the bespoke orthotics we produce.

How we manufacture our orthotics on-site

Because our manufacturing unit is on-site at our headquarters clinic in Kingston upon Thames, we can offer patients many benefits. Our orthotists and technicians work closely together to produce the highest quality bespoke orthotics in the UK.

We do not have to rely on outside suppliers, so we’re able to exercise exacting quality control and produce even complex orthotics considerably faster. In some cases, this is within 48 hours.

This close partnership between orthotist and technician means that quite subtle design requirements can be incorporated into each orthosis we produce.

This can make all the difference in terms of fit and comfort and optimises the effect of the original orthotic prescription. Even at the fitting stage, we can fine-tune our orthotics quickly and easily.

Specialist manufacturing capabilities

Cutting edge technologies

We are constantly innovating for the benefit of our patients, with new cutting-edge technology to aid both design and manufacture including:

• CAD/CAM design and manufacture
• Carbon fibre orthotics
• Victor the 7-axis robot
• CAD/CAM third party milling services provided by Victor

3D printing workshop

We are increasingly looking at ways to revolutionise and optimise our bespoke orthotics with additive manufacturing (3D printing). Our in-house design team developed the new LOCband Lite based upon HP’s Multijet Fusion technology (MJF).

This new 3D printed cranial helmet features a lightweight design thanks to the thinner wall thickness and vented meshes. This has a number of tangible benefits for our patients: much more cooling due to greater heat dissipation and reduced neck strain (torticollis) due to a lightweight design.

Carbon fibre workshop

At the London Orthotic Consultancy, we specialise in crafting bespoke carbon fibre orthotics using advanced prepreg carbon fibre technology in our in-house manufacturing lab.

This cutting-edge material offers exceptional strength, reduced weight, and a slim profile, resulting in orthoses that are more durable, comfortable, and energy-efficient than those made with traditional materials. Ideal for individuals with complex musculoskeletal or neurological conditions, our carbon fibre orthotics enhance mobility, endurance, and overall clinical outcomes—empowering patients to walk further, faster, and with greater confidence.

Robotic technology

Victor is a seven-axis CNC (Computer Numerical Control) milling machine manufactured by Rodin4D that can precisely mill orthotic moulds in any direction and across any plane.

For the first time, we can design, model and manufacture trickier and unusual ergonomic orthotic (body) shapes onsite at our clinic in Kingston-upon-Thames.

The London Orthotic Consultancy is only the second location in the UK to have a robot with Victor’s capabilities.

Experienced craftsmanship

Our manufacturing technicians have a wide array of experience between them. Their specialisms uphold the best traditions of craftsmanship in metalwork and leatherwork, as well as insoles, plaster, and pre-preg carbon fibre in our bespoke AFOs and KAFOs.