When it comes to orthotic prescriptions, one size does not fit all, especially when it comes to the materials used. While EVA remains a commonly used material in clinical practice, advancements in technology have introduced a new generation of orthotic materials that better meet the needs of diverse patient lifestyles. At Orthotech, we offer a suite of advanced materials, including PA11, Poly-X, and carbon fibre composites to support more tailored, durable, and effective orthotic therapy.
What are the best orthotic materials for active patients?
Active patients, whether professional athletes, weekend warriors, or those on their feet all day, place high physical demands on their orthotics. The best materials for these individuals offer durability, structural integrity, and shock-absorbing properties without adding unnecessary bulk.
- PA11 (3D Printed Nylon) is strong, flexible, and lightweight. It adapts well to active use while maintaining comfort.
- Carbon Fibre Composites provide high control and responsiveness, especially valuable for high-performance sports applications.
These materials are designed to endure repetitive stress and provide biomechanical support through high-impact activities.
How does PA11 differ from traditional orthotic materials?
PA11 is a bio-based nylon used in Orthotech’s 3D printing process. It offers several advantages over traditional EVA:
- It is stronger and more durable under stress.
- The 3D printing process enables precise anatomical details and a perfect fit.
- It is lighter and thinner than most traditional materials, improving footwear compatibility.
Unlike EVA, which can compress over time, PA11 retains its structure and provides longer-lasting correction.
When should I prescribe a carbon fibre orthotic?
Carbon fibre is best suited for patients requiring:
- High levels of control for significant biomechanical corrections
- A low-profile fit for formal or tight-fitting footwear
- Enhanced energy return for athletic performance
Due to its rigidity, carbon fibre may not suit all patients but is highly effective in performance-driven or correction-intensive cases.
What’s the most durable material for custom orthotics?
Durability of custom orthotics depends on a patient’s activity level, footwear, and environment. However, some materials are known for exceptional longevity:
- Carbon Fibre Composite: Outstanding for structural integrity and minimal wear.
- PA11: Offers long-term flexibility and endurance.
- Poly-X: Proprietary to Orthotech, this material balances strength and comfort, performing well under daily wear conditions.
These options significantly outlast traditional EVA, especially under sustained load or activity.
How do different orthotic materials affect patient comfort and performance?
Material selection impacts not only the longevity of the orthotic but also its comfort and performance for the patient. Here is a quick comparison:
| Material | Comfort Level | Support & Control | Ideal Use Case |
| EVA | Very soft | Low to moderate | Sensitive feet, diabetic care |
| PA11 | Balanced | Moderate to high | Active patients, complex foot shapes |
| Poly-X | Firm yet forgiving | Moderate | All-day use, occupational orthotics |
| Carbon Fibre | Rigid, less forgiving | High | Athletes, slim-fit footwear |
Choosing the right custom orthotic material isn’t just about comfort—it’s about achieving better outcomes for your patients. Advanced materials like PA11, Poly-X, and carbon fibre give clinicians greater control, precision, and performance across a range of patient needs. Whether treating an athlete, a tradesperson, or someone with specific biomechanical concerns, material matters.
Want to match the right material to the right patient?
We’re here to support your clinical decisions with guidance and high-quality options.
- Book an introductory webinar: https://orthotech.com.au/bookings/
- Learn more about our advanced orthotic materials: https://orthotech.com.au/materials/