Materials

The best quality materials at the best possible prices.

Discovery Orthotics source materials of the highest quality to maximise longevity and presentation of our devices. We are continuously looking for advancements and improvements in the materials we use to ensure we can provide the best devices to you.

Our comprehensive range of materials provides you with the choice needed to fulfil all your prescription needs. In the unlikely event that we do not have a material to suit your needs or prescribing methods then please contact us and we will endeavour to source the ideal material for use on your devices.

Take a look at our products...

Materials image

Our materials

  • All materials
  • Base material
  • Mid layer
  • Pads
  • Top covers
  • Under sole additions

Aortha Airlite

Beige

3mm

Low density EVA
Mouldable
Abrasion resistance

Common uses:
Top covers
Mid layer
Custom pads

Black Leather

Black

1mm

Cape nappa leather
Premium finish
For use with intact skin only

Common uses:
Top covers

Black Polypropylene

Black

30mm

High strength to weight ratio
Flexible
Strong durable devices

Common uses:
CAD Insole base

Carbonium

Black | Blue

1mm

Carbonfibre effect
Smooth and durable
Premium finish

Common uses:
Top covers

Chamois

Beige

1.5mm

Highly absorbent
Hard wearing material
For use with intact skin only

Common uses:
Top covers

Dual density EVA Shore A25/A50

Blue | Green

35mm

Combination of EVA densities
More choice
Greater functionality

Common uses:
CAD Insole base

Dual density EVA Shore A40/50

Beige | Green

35mm

Combination of EVA densities
More choice
Greater functionality

Common uses:
CAD Insole base

Dual density EVA Shore A50/A75

Green | Red

35mm

Combination of EVA densities
More choice
Greater functionality

Common uses:
CAD Insole base

High density sheet EVA

Black

3mm | 6mm | 10mm

Shore A65
Versitile material
Durable

Common uses:
Custom pads
Under sole additions
Simple insole base
Traditional base

High density wedging

Grey | Beige

3.5° (Grey) | 5° (Beige)

Hard wearing
Provides control
Multitude of uses

Common uses:
Under sole addition

Leatherboard

Tan

1mm

Ideal base for simple devices
Forefoot stiffener
Excellent template material

Common uses:
Simple insole base
Extensions/Stiffener

Low density wedging

White

Soft
Provides control
Multitude of uses

Common uses:
Under sole addition

Marble EVA

Black | Blue | Beige

1mm

Soft
Comfortable
High quality

Common uses:
Top covers

Medium density sheet EVA

Black

3mm | 6mm | 8mm | 10mm | 12mm

Shore A50
Versitile material
Durable

Common uses:
Custom pads
Under sole additions
Simple insole base
Traditional base

Medium density wedging

Yellow | Black

4° (Black) | 5° (Yellow)

Provides control
Multitude of uses
Softer

Common uses:
Under sole addition

Microfibre

Black | Blue | Tan

1mm

Soft
Absorbent
Premium finish

Common uses:
Top covers

Natural Leather/Pigskin

Tan

1mm

Hard wearing
Breathable
For use with intact skin only

Common uses:
Top covers

Natural Polypropylene

Natural

30mm | 40mm

High strength to weight ratio
Flexible
Strong durable devices

Common uses:
CAD Insole base

Neosorb

Black

1.5mm

Hard wearing and durable
Comfortable
Premium finish

Common uses:
Top covers

Nora Aerosorb

Red

3mm | 6mm

Outstanding bedding characteristics
Thermoformable material
Ideal for deep heel cups

Common uses:
Top covers
Mid layer

Nora Aerosorb Green

Green

3mm | 6mm

Softer than red
Outstanding bedding characteristics
Ideal for deep heel cups

Common uses:
Top covers
Mid layer

Nora Lunairmed

Beige

2mm | 3mm

Very soft
Highly resilient
High walking comfort

Common uses:
Top covers
Mid layer
Custom pads

Nora Lunasoft SL

Beige

2mm | 3mm

Lightweight
Flexible
High walking comfort

Common uses:
Top covers
Mid layer
Custom pads
Simple insole base

Nora Lunatec Motion

Grey

3mm

Very soft
Absorbtion of shearing forces
Ideal bedding material

Common uses:
Top covers

Patterned EVA

Black and Yellow | Blue and Green Camo | Purple and Black Camo

1mm

Soft
Comfortable
High quality

Common uses:
Top covers

Perforated EVA (Aortha Airlife)

Beige

3mm

Improved air flow
Mouldable
Abrasion resistance

Common uses:
Top covers

Perforated Microfibre

Black | Tan

1mm

Perforated
Comfortable
Premium finish

Common uses:
Top covers

Plain EVA

Black | Blue

1mm

Soft
Comfortable
High quality

Common uses:
Top covers

Plastazote HD

Black

12mm

Discourages bacteria growth
Good insulating properties
Predominately used for toe blocks

Common uses:
Custom pads

Plastazote LD

White

3mm | 6mm

Easily heat moulded
Discourages bacteria growth
Good insulating properties

Common uses:
Top covers

Poron 4000

Grey

1.6mm | 3.2mm | 6.3mm

Superior comfort
Exceptional energy absorption
Dimensional stability

Common uses:
Top covers
Mid layer
Custom pads
Simple insole base

Poron 92

Red

3.2mm | 6.3mm

Ultra soft
Slow rebound
Ideal for soft spots

Common uses:
Infilling dells
Heel cushion
Mid layer

Poron 94

Pink

3.2mm | 6.3mm

Soft
Lightweight
Slow rebound

Common uses:
Top covers
Mid layer
Custom pads

Poron 96

Patina

3.2mm | 6.3mm

Excellent impact absorption
Contours to the foot
Antifungal

Common uses:
Top covers
Mid layer
Custom pads

Poron Dual Layer

Pink | Blue

4mm

Bottom layer is Poron 4000
Top layer is Poron 94
Slow rebound redistributes pressure

Common uses:
Top covers

Poron Vive

Green

3.2mm

Reduced pressure at load points
High energy return
Excellent shear abraison

Common uses:
Mid layer

Poron XRD

Yellow

3.2mm

Soft to the touch
Lightweight
Absorbs energy upon repeated impact

Common uses:
Top covers
Mid layer
Custom pads

Pre-covered Polyurethane

Blue polyurethane with black cover

3.2mm

Polyurethane base
Fabric top cover pre-applied
Only for use in low heel cups

Common uses:
Top covers

PU Backed Microfibre

Black

1mm

Soft
Absorbent
Premium finish

Common uses:
Top covers

Pu metertarsal pad

Blue

4mm small | 6mm medium | 7mm large

High raise
Prefabricated
Self adehesive backing

Common uses:
Prefabricated pad

Shore A18 EVA

Blue

35mm

Ultra low density EVA
Very soft
CAD CAM manufacturing

Common uses:
CAD Insole base

Shore A25 EVA

Beige

35mm

Low density EVA
Cushioning
CAD CAM manufacturing

Common uses:
CAD Insole base

Shore A40 EVA

Beige

35mm

Medium/Low density EVA
More supportive
CAD CAM manufacturing

Common uses:
CAD Insole base

Shore A50 EVA

Black

35mm

Medium density EVA
Supportive and durable
CAD CAM manufacturing

Common uses:
CAD Insole base

Shore A60 EVA

Beige

35mm

High density EVA
Hard wearing
CAD CAM manufacturing

Common uses:
CAD Insole base

Soft foam metertarsal pad

Grey

Size 1 | Size 2

Teardrop shaped
Soft foam low density
Flat

Common uses:
Prefabricated pad

Thermo Plastic

Red

4mm

Used in traditional manufacturing

Common uses:
Traditional base

Yampi Synthetic Leather

Black

1mm

Good low temperature flexibility
High resistance to abrasion
Durable

Common uses:
Top covers

Discovery Orthotics

UKAS-ISO-9001

We manufacture custom-made podiatry orthotics for businesses and NHS organisations all over the UK.

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Testimonials

I would like to say an amazing thank you to the team for their attention to detail and quick advice regarding any queries and problems with our orders. I have also been most impressed with the urgency attended to orders that I have required on a quick turnaround for clinic appointments. Keep up the good work.

Senior Orthotics Officer
Guy’s and St Thomas’ NHS Foundation Trust

The service I have received from you has been really great. The best from any lab I’ve worked with.

Lawrence Bevan
Private Practitioner

This has been an exemplar of partnership working, which has benefited both parties. It has been a pleasure to work with the Orthotics Team in Kent; they have been highly responsive to our requests.

Deputy Podiatric and Orthotic Services Manager
Cwm Taf University Health Board

The service is first-class. There is an outstanding team of very experienced technicians, with excellent management and administrative support. The products are good, the turn-round fast and the prices are competitive. Most importantly, they are always on hand to give advice and alter devices at short notice.

Emma Stevens-Tonks
CSH Surrey

Crown copyright. Discovery Orthotics is the orthotic manufacturing department of Kent Community Health NHS Foundation Trust.

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