Comparison:
Traditional vs. Our System
Comparison:
Traditional vs. Our System
Healsy outperforms casting
and 3D printing in every way
Our advanced system delivers superior results across all categories from material variety and modifiability to production speed and cost efficiency.
Unlike traditional methods such as casting or limited 3D printing options, Healsy provides a smarter, faster, and more flexible solution tailored to clinical demands.
Traditional vs Our System
Smart Questions. Smarter Orthotics.
Why choose Healsy over other systems?
Why choose Healsy over other systems?
Current polypropylene shell is heavy, rigid, and difficult to modify after production.
3D printing offers some precision, But uses limited materials, isn’t adjustable, and often creates waste. Healsy allows full customization with diverse thermoformable materials, on-the-spot modification, faster turnaround 5-7 days, and eco-conscious production.
Current traditional way is heavy, rigid, and difficult to modify after production. 3D printing offers some precision, But uses limited materials, isn’t adjustable, and often creates waste. Healsy allows full customization with diverse thermoformable materials, on-the-spot modification, faster turnaround 5–7 days, and eco-conscious production.
How does the order process work?
You don’t need to know all materials,
just tell us what the patient needs.
STEP 1. Scan the foot using our iPad & App.
STEP 2. Fill out the prescription and submit.
STEP 3. We build and ship the custom orthotics within 24 hours.
Material
Material
Material
Material
Material
The Healsy Custom Orthotic combines more than 60 materials and more than 30,000 materials to create the most ideal guide for your purpose with an infinite combination of layers. The pattern design for each user has improved functionality and provides a customized guide for 100% of the user's feet with various elements.
The Healsy Custom Orthotic combines more than 60 materials and more than 30,000 materials to create the most ideal guide for your purpose with an infinite combination of layers. The pattern design for each user has improved functionality and provides a customized guide for 100% of the user's feet with various elements.
The Healsy Custom Orthotic combines more than 60 materials and more than 30,000 materials to create the most ideal guide for your purpose with an infinite combination of layers. The pattern design for each user has improved functionality and provides a customized guide for 100% of the user's feet with various elements.
The Healsy Custom Orthotic combines more than 60 materials and more than 30,000 materials to create the most ideal guide for your purpose with an infinite combination of layers. The pattern design for each user has improved functionality and provides a customized guide for 100% of the user's feet with various elements.
The Healsy Custom Orthotic combines more than 60 materials and more than 30,000 materials to create the most ideal guide for your purpose with an infinite combination of layers. The pattern design for each user has improved functionality and provides a customized guide for 100% of the user's feet with various elements.
Top Cover
Bases
Technical Materials
Correction
Elements
Antibacterial, breathable, durable, and skin-friendly
for long-lasting comfort and hygiene.
The core layer of the insole, made from thermoformable
materials with varying support and elasticity.
Components that support shock absorption,
propulsion, and sensory feedback.
Improves alignment, pressure distribution, and balance
with varied Shore hardness and densities.
Attachable components used to precisely correct
or support specific pathologies or anatomical issues.
Ideal for running, trekking, cycling, and daily use, with a range of textures and 0.7–3mm+ thickness options for precise fitting. Durable over time and gentle on sensitive skin.
Its stiffness and resilience help maintain shape and provide support based on gait and weight. Offered in slim, standard, and wide shells with 1–4mm thickness for precise customization by podiatrists.
Available in various Shore hardness and densities, they absorb impact, convert energy into rebound force, and can be selectively placed to relieve pain or stimulate targeted areas.
They can be freely positioned and adjusted in thickness based on pathology or movement patterns, maintain shape after thermoforming, and enable precise structural correction by podiatrists.
With varied hardness and density, they adjust alignment, pressure, motion control, and leg length. Applied in or on orthotics for tailored support and flexibility.
Thickness 0.4mm
Thickness 0.7, 1mm
Rigid 10/10
Thickness 1.5mm
Hardness Shore A +/- 30
Density 650kg/m3
Thickness
7mm
Hardness
Shore A +/- 60
Hardness
Shore A +/- 45
Thickness 0.7mm
Thickness 0.8, 1.2, 1.9mm
Rigid 5/10
Thickness 2mm
Hardness Shore A +/- 30
Density 160kg/m3
Thickness
2.4mm
Hardness
Shore A +/- 60
Thickness
5mm
Hardness
Shore A +/- 50
Thickness 0.5mm
Thickness 1.3mm
Rigid 6/10
Thickness 3mm
Hardness Shore A +/- 30
Density 240kg/m3
Thickness
2.4mm
Hardness
Shore A +/- 60
Thickness
5mm
Hardness
Shore A +/- 50
Thickness 2.5mm
Hardness Shore A +/- 30
Density 140kg/m3
Thickness 0.8mm
Rigid 4/10
Thickness 1.5mm
Hardness Shore A +/- 25
Density 450kg/m3
Hardness
Shore A +/- 60
Thickness
5mm
Hardness
Shore A +/- 50
Thickness 2mm
Hardness Shore A +/- 22
Density 170kg/m3
Thickness 1.5mm
Rigid 6/10
Thickness 3mm
Hardness Shore A +/- 17
Density 330kg/m3
Hardness
Shore A +/- 45
Thickness
10mm
Hardness
Shore A +/- 24
Thickness 2.5, 5, 8mm
Hardness Shore A +/- 22
Density 155kg/m3
Thickness 1, 1.2mm
Rigid 7/10
Thickness 2mm
Hardness Shore A +/- 10
Density 250kg/m3
Thickness
5mm
Hardness
Shore A +/- 50
Thickness
6mm
Hardness
Shore A +/- 56
Thickness 2.5mm
Hardness Shore A +/- 30
Density 110kg/m3
Thickness 5, 15, 20mm
Hardness Shore A +/- 55
Density 160kg/m3
Thickness 3mm
Hardness Shore A +/- 17
Density 500kg/m3
Thickness
5mm
Hardness
Shore A +/- 50
Thickness
6mm
Hardness
Shore A +/- 70
Thickness 2mm
Hardness Shore A +/- 30
Density 110kg/m3
Thickness 2, 3, 5, 7, 10, 15mm
Hardness Shore A +/- 56
Density 170kg/m3
Thickness 4mm
Hardness Shore A +/- 15
Density 700kg/m3
Thickness
5mm
Hardness
Shore A +/- 50
Thickness
6mm
Hardness
Shore A +/- 70
Thickness 2.5mm
Hardness Shore A +/- 30
Density 110kg/m3
Thickness 1.5mm
Hardness Shore A +/- 55
Density 250kg/m3
Thickness 4mm
Hardness Shore A +/- 10
Density 130kg/m3
Thickness
10mm
Hardness
Shore A +/- 24
Thickness
10mm
Hardness
Shore A +/- 24
Thickness 0.8mm
Thickness 1.5mm
Hardness Shore A +/- 55
Density 285kg/m3
Thickness 4mm
Hardness Shore A +/- 25
Density 150kg/m3
Thickness
6mm
Hardness
Shore A +/- 56
Thickness
6mm
Hardness
Shore A +/- 56
Thickness 0.8mm
Thickness 1mm
Rigid 6/10
Thickness 10mm
Hardness
Shore A between 22 and 28
Density 240-250kg/m3
Thickness
6mm
Hardness
Shore A +/- 70
Thickness
6mm
Hardness
Shore A +/- 70
Thickness 3.2mm
Hardness Shore A +/- 10
Density 400kg/m3
Thickness 1.6mm
Rigid 7/10
Thickness 4mm
Hardness
Shore A between 22 and 28
Density 270-280kg/m3
Thickness
5mm
Hardness
Shore A +/- 56
Thickness
6mm
Hardness
Shore A +/- 70
Material
The Healsy Custom Orthotic combines more than 60 materials and more than 30,000 materials to create the most ideal guide for your purpose with an infinite combination of layers. The pattern design for each user has improved functionality and provides a customized guide for 100% of the user's feet with various elements.
Top Cover
Hardness Shore A +/- 30
Density 140kg/m3
Hardness Shore A +/- 22
Density 170kg/m3
Hardness Shore A +/- 22
Density 155kg/m3
Hardness Shore A +/- 30
Density 110kg/m3
Hardness Shore A +/- 30
Density 110kg/m3
Hardness Shore A +/- 30
Density 110kg/m3
Hardness Shore A +/- 10
Density 400kg/m3
Hardness Shore A +/- 30
Density 140kg/m3
Hardness Shore A +/- 22
Density 170kg/m3
Hardness Shore A +/- 22
Density 155kg/m3
Hardness Shore A +/- 30
Density 110kg/m3
Hardness Shore A +/- 30
Density 110kg/m3
Hardness Shore A +/- 30
Density 110kg/m3
Hardness Shore A +/- 10
Density 400kg/m3
Antibacterial, breathable, durable, and skin-friendly
for long-lasting comfort and hygiene.
Ideal for running, trekking, cycling, and daily use, with a range of textures and 0.7–3mm+ thickness options for precise fitting. Durable over time and gentle on sensitive skin.
Bases
Rigid 10/10
Rigid 5/10
Rigid 6/10
Rigid 4/10
Rigid 6/10
Rigid 7/10
Hardness Shore A +/- 55
Density 160kg/m3
Hardness Shore A +/- 56
Density 170kg/m3
Hardness Shore A +/- 55
Density 250kg/m3
Hardness Shore A +/- 55
Density 285kg/m3
Rigid 6/10
Rigid 7/10
Rigid 10/10
Rigid 5/10
Rigid 6/10
Rigid 4/10
Rigid 6/10
Rigid 7/10
Hardness Shore A +/- 55
Density 160kg/m3
Hardness Shore A +/- 56
Density 170kg/m3
Hardness Shore A +/- 55
Density 250kg/m3
Hardness Shore A +/- 55
Density 285kg/m3
Rigid 6/10
Rigid 7/10
The core layer of the insole, made from thermoformable materials with varying support and elasticity.
Its stiffness and resilience help maintain shape and provide support based on gait and weight. Offered in slim, standard, and wide shells with 1-4mm thickness for precise customization by podiatrists.
Technical Materials
Hardness Shore A +/- 30
Density 650kg/m3
Hardness Shore A +/- 30
Density 160kg/m3
Hardness Shore A +/- 30
Density 240kg/m3
Hardness Shore A +/- 25
Density 450kg/m3
Hardness Shore A +/- 17
Density 330kg/m3
Hardness Shore A +/- 10
Density 250kg/m3
Hardness Shore A +/- 17
Density 500kg/m3
Hardness Shore A +/- 15
Density 700kg/m3
Hardness Shore A +/- 10
Density 130kg/m3
Hardness Shore A +/- 25
Density 150kg/m3
Hardness Shore A
between 22 and 28
Density 240-250kg/m3
Hardness Shore A
between 22 and 28
Density 270-280kg/m3
Hardness Shore A +/- 30
Density 650kg/m3
Hardness Shore A +/- 30
Density 160kg/m3
Hardness Shore A +/- 30
Density 240kg/m3
Hardness Shore A +/- 25
Density 450kg/m3
Hardness Shore A +/- 17
Density 330kg/m3
Hardness Shore A +/- 10
Density 250kg/m3
Hardness Shore A +/- 17
Density 500kg/m3
Hardness Shore A +/- 15
Density 700kg/m3
Hardness Shore A +/- 10
Density 130kg/m3
Hardness Shore A +/- 25
Density 150kg/m3
Hardness Shore A
between 22 and 28
Density 240-250kg/m3
Hardness Shore A
between 22 and 28
Density 270-280kg/m3
Components that support shock absorption,
propulsion, and sensory feedback.
Available in various Shore hardness and densities,
they absorb impact, convert energy into rebound force,
and can be selectively placed to relieve pain or stimulate targeted areas.
Correction
7mm
Hardness
Shore A +/- 60
2.4mm
Hardness
Shore A +/- 60
2.4mm
Hardness
Shore A +/- 60
Shore A +/- 60
Shore A +/- 45
5mm
Hardness
Shore A +/- 50
5mm
Hardness
Shore A +/- 50
5mm
Hardness
Shore A +/- 50
10mm
Hardness
Shore A +/- 24
6mm
Hardness
Shore A +/- 56
6mm
Hardness Shore
A +/- 70
5mm
Hardness
Shore A +/- 56
Improves alignment, pressure distribution, and balance with varied Shore hardness and densities.
They can be freely positioned and adjusted in thickness based on pathology or movement patterns, maintain shape after thermoforming, and enable precise structural correction by podiatrists.
Elements
Shore A +/- 45
5mm
Hardness
Shore A +/- 50
5mm
Hardness
Shore A +/- 50
5mm
Hardness
Shore A +/- 50
10mm
Hardness
Shore A +/- 24
6mm
Hardness
Shore A +/- 56
6mm
Hardness
Shore A +/- 70
6mm
Hardness
Shore A +/- 70
10mm
Hardness
Shore A +/- 24
6mm
Hardness
Shore A +/- 56
6mm
Hardness Shore
A +/- 70
6mm
Hardness
Shore A +/- 70
Attachable components used to precisely correct or support specific pathologies or anatomical issues.
With varied hardness and density, they adjust alignment, pressure, motion control, and leg length. Applied in or on orthotics for tailored support and flexibility.
Pattern
Healsy Custom Orthotics takes into account numerous factors such as the insole’s intended purpose, the wearer’s foot condition, and the type of shoe and offers design patterns engineered with region specific materials of varying thicknesses and properties to deliver both stability and comfort.
Modules and material patterns
tailored to specific foot conditions
Modules and material patterns
for sports and everyday use
Layered Combination
Healsy Custom Orthotics takes into account numerous factors such as the insole’s intended purpose, the wearer’s foot condition, and the type of shoe and offers design patterns engineered with region specific materials of varying thicknesses and properties to deliver both stability and comfort.
Ultra-fine top layer for moisture wicking and antimicrobial protection.
Custom shock-absorbing inserts
to reduce impact on heel strike
High-density base for structural support and lasting stability
Material Design Parameters
for Healsy Custom Orthotics
The materials used to produce Healsy Custom Orthotics are designed according to pattern guidelines to meet the following objectives and characteristics.
Layering
3-7 stacked layers providing sensory padding, shock absorption, propulsion, stability, arch support, resilience, and abrasion resistance.
Shock-Absorption Layer
Materials with high energy-dissipation capability to cushion impact.
Resilience
Combinations engineered for superior rebound and recovery, reducing fatigue during extended wear.
Propulsion
Designed to support forward momentum and enhance gait efficiency.
width
Available in slim, standard, and wide selected according to shoe type and the user’s foot volume.
Thickness
Multiple material thicknesses tailored to the shoe and intended use, allowing adaptation to each user’s needs.
Shell Type
Full shell, ¾-shell, arch shell, etc. stability is adjusted based on activity and biomechanical requirements.
Pattern
Various support and cushioning patternsm edial reinforcement, forefoot shock absorbing zones, heel-cup designs and more.
Stiffness
Adjustable through material density, Shore hardness, and thickness.
Layering
3-7 stacked layers providing sensory padding, shock absorption, propulsion, stability, arch support, resilience, and abrasion resistance.
Shock-Absorption Layer
Materials with high energy-dissipation capability to cushion impact.
Resilience
Combinations engineered for superior rebound and recovery, reducing fatigue during extended wear.
Propulsion
Designed to support forward momentum and enhance gait efficiency.
width
Available in slim, standard, and wide selected according to shoe type and the user’s foot volume.
Thickness
Multiple material thicknesses tailored to the shoe and intended use, allowing adaptation to each user’s needs.
Shell Type
Full shell, ¾-shell, arch shell, etc. stability is adjusted based on activity and biomechanical requirements.
Pattern
Various support and cushioning patternsm edial reinforcement, forefoot shock absorbing zones, heel-cup designs and more.
Stiffness
Adjustable through material density, Shore hardness, and thickness.
CAD & Insole Fabrication
Healsy’s CAD system is a specialized software–based platform that captures the podiatrist’s expertise with precision. Using the patient’s foot data, practitioners can design orthotic shapes and corrective features such as arch height, rear‐foot alignment, and pressure distribution zones tailored to each order and visualize them in 3D. This digital design workflow ensures high fidelity, consistent quality, and time efficiency, delivering results optimized for clinical needs.
Healsy Custom Orthotics are handcrafted by skilled technicians who precisely combine thermoformable materials with a variety of modules, multi layer constructions, and corrective elements. Each insole is custom designed based on the patient’s foot condition, intended activity, and shoe type delivering not just functional support but also clinical accuracy and optimized fit. The thermoforming process, engineered for exact fitting and functional integrity, maximizes both conformity to the foot and corrective efficacy, providing a high-quality insole solution that satisfies medical requirements and enhances sports performance alike.
Healsy Custom Orthotic
Healsy Custom Orthotic is a truly custom insole combining bespoke shaping, some 30,000 material combinations, and diverse patterns and elements. While traditional insoles have targeted treatment of podiatric conditions, Healsy expands the market to everyday use, sports, and a wide range of other purposes.
Foam Heel Base
Podiane+ 2mm and Progrip 0.8mm
Hardness: shore A +/- 15
Density: 700 kg/m3
Formulation: Polynorbornene-based elastomer foam
This foam base material is designed to cushion and absorb shock waves. It has excellent cushioning and perfect resistance.
Over-liner
Transflux 1mm
Formulation: Flowing polyester resin
This material has good responsiveness,
high flexion and great rigidity.
Midfoot liner
Transflux® 1.5mm
Formulation: Flowing polyester resin
This material has good responsiveness,
high flexion and great rigidity
Top cover
Evamic.arg MP 2.5mm
Hardness: shore A +/- 22
Density: 155 kg/m3
Formulation: PE-EVA foam
This material is comfortable and highly flexible. It has good
elasticity, is very stretchable and compressible
(silver ion treatment)
Midfoot liner
Podiaflex 1.2mm
Formulation: Polyester resin
This resin has a high PVC content which gives it good robustness, flexibility, responsiveness and rigidity.
Forefoot
Expertene 400 1.5mm
Hardness: Shore A +/- 10
Density: 400 kg/m3
Formulation: Polyurethane foam
This material is designed with a very good density/Shore ratio, which makes it ideal for the forefoot. It has excellent cushioning, great durability and good dynamism. Ideal for slim footwear.
CONTACT US
Homepage Privacy policy
At Healsy Orthotics
we are committed to protecting your privacy. This policy outlines how we collect, use, store, and disclose your personal information in accordance with the Australian Privacy Principles.
INFORMATION WE COLLECT
When you visit our website, interact with our staff, utilise our software, or use our products and services, we may collect the following personal information ("Personal Data")
Full name
Company name
Occupation
Email address
Phone number
Payment details
Billing address
Geographic location
IP address
Survey responses, reviews and testimonials
We may also collect information in relation to your Patients including
Names
Gender
Date of Birth
Medical Scans results
Reviews and testimonials
You can access or amend your Personal Data by logging into your account or contacting us directly.
Please note that any information you publish on our website (e.g. blog comments or testimonials) may be publicly accessible. Even if you delete this content, cached versions may still be viewable elsewhere.
USE OF YOUR INFORMATION
We use your Personal Data to
Provide and deliver our products and services
Process payments
Communicate with you
Send updates, offers, and service notifications
Gather feedback and measure customer satisfaction
Personalise your website experience
You will only receive marketing communications if you have opted in. You can unsubscribe at any time via the link in our emails or by contacting us.
Our website also uses digital identifiers such as cookies to enhance your browsing experience by
Analysing website traffic and usage
Enable social media sharing features
Provide targeted advertising through third-party platforms
Most browsers accept cookies automatically, but you can disable them via your browser settings. Doing so may limit some functionality of our website.
We may use anonymised and aggregated data (non-personally identifiable information) to
Improve our services and website functionality
Analyse customer behaviour and website usage
Serve targeted advertisements via platforms such as Google Ads and Facebook
STORAGE AND SECURITY OF DATA
We take reasonable steps to protect your Personal Data from loss, misuse, unauthorised access, or disclosure via the following protocols.
All data is stored securely on our protected servers.
Personal data stored in paper records at our company will be physically secured.
We will not record any payment information. Credit card data is encrypted during transmission and is not stored on our systems.
Personal Data may be stored or processed outside of Australia, but only in countries that provide adequate data protection.
We retain Personal Data for only as long as necessary to provide services and comply with our legal obligations.
If a data breach occurs and your information is affected, we will notify you in accordance with applicable laws.
SHARING OF YOUR INFORMATION
We do not sell, trade, or rent your Personal Data to any third party.
Your information may be shared with third parties only when necessary to
Fulfill purchases and process payments
Provide technical and marketing support
Deliver IT infrastructure and related services
Comply with legal or regulatory requirements
Protect our rights, property, or safety
Any third-party service providers we engage are required to uphold the same privacy standards outlined in this policy and are prohibited from using your data for any purpose other than providing services on our behalf.
ACCESS TO PERSONAL INFORMATION
If you ask us, we will give you access to the personal information we hold about you. We will always confirm your identity before giving access to your personal information. However, there are circumstances under Australian privacy laws where we may not give you access to the personal information we hold about you. For example, we can’t give you access if it would unreasonably affect someone else’s privacy or if giving you access poses a serious threat to someone’s life, health or safety.
LEGAL DISCLOSURES
We may disclose Personal Data if required by law or in connection with legal proceedings, regulatory investigations, or enforcement actions.
In the event of a business transfer (e.g. merger or sale), customer information may be transferred to the new owner under a confidentiality agreement.
EXTERNAL LINKS
Our website may contain links to third-party websites for your convenience. We are not responsible for the privacy practices or content of external sites. We encourage you to review their privacy policies before providing any personal information.
CHANGE IN PRIVACY POLICY
We may from time to time update our privacy policy to ensure remains current. If we decide to so, all updates will be effective immediately upon being published.
CONTACT US
If you have any queries or concerns about our privacy policy or the use of your Personal Data, please contact us at contact@heasly.com.au