In this episode of the Podiatry Legends Podcast, I’m joined by returning guest Kieran Carew from www.foothealthorthotics.co.uk FIT4, to explore one of the biggest shifts currently happening in podiatry: 3D printed orthotics.
Kieran was last on the podcast back in 2020, discussing pathology-based orthotics. Fast forward to today, and he’s now deeply involved in developing, testing, and installing 3D printing systems in podiatry clinics worldwide.
This episode is not a sales pitch for technology. It’s a practical, honest discussion about what’s working, what hasn’t, and what podiatrists need to understand before adopting new systems.
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From Engineering to Clinic Reality
Kieran shares how his background in mechanical engineering and sports science shaped the early development of in-clinic 3D printing. One of the biggest lessons? Technology alone isn’t enough.
Early systems required excessive manual calibration and technical input, creating frustration for busy clinicians. The breakthrough came when podiatrists' feedback directly shaped the next generation of printers, resulting in plug-and-play systems designed specifically for clinical environments.
Control, Cost, and Turnaround
One of the strongest themes in this episode is control.
Kieran explains how clinics are reducing orthotic production costs by lowering lab fees from £120–£150 to as little as £10–£12 per pair when designing and printing in-house. Even when clinics outsource the CAD design, the cost savings and turnaround times remain significant.
This isn’t just about saving money. Faster turnaround means better patient experiences and fewer delays in care.
CAD Design and Education Matter
A recurring message throughout the conversation is that education is essential. 3D printing is most effective when podiatrists understand biomechanics, design principles, and material behaviour.
Kieran explains how CAD software gives clinicians full control over orthotic design, including infill density, flexibility, and targeted accommodation based on pressure data. This level of precision simply isn’t possible with traditional workflows.
The Marketing Advantage of Visibility
One of my favourite parts of the discussion is how 3D printers can become a visual asset in a clinic.
Placed in reception areas, printers spark curiosity, conversations, and social media sharing. Clinics using visible technology are seeing increased patient engagement and higher orthotic uptake, simply because patients can see innovation happening in real time.
I have a coaching client who installed a 3D printer in their reception area, which immediately generated curiosity, more orthotic conversations, and an increase in monthly orthotic numbers.
Is This the Future of Podiatry?
We also talk about the broader industry shift.
Rising lab costs, staff shortages, and clinic pressure are pushing podiatrists to rethink traditional models. 3D printing isn’t a trend; it’s part of a broader shift toward efficiency, ownership, and smarter systems.
Considering Your Next Step
If this episode has you thinking differently about orthotics, systems, or clinic workflows, you’re not alone. These are the exact conversations I have with podiatrists through my coaching and mentoring work.
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