Custom Orthotics Newcastle — 3D Printed by Podiatrists
The only Newcastle podiatry clinic using 3D scanning, in-house design and printing to make custom orthotics. Better fit, faster turnaround, no plaster casts.
No GP referral needed · HICAPS on-site · Most private health funds · Same-week appointments
If foot pain is changing how you walk, train, work or sleep, the cause is usually mechanical — and it's usually fixable. Custom orthotics are medical-grade shoe inserts shaped to your feet, designed by a podiatrist to take pressure off the structures that are hurting and put your gait back into a stronger position.
At East Coast Podiatry Clinic in Charlestown, we use a 3D foot scanner, orthotic design software and 3D printer instead of the plaster casting most clinics still rely on. The result is a more precise device, a shorter wait, and orthotics that hold their shape for years.
Foot conditions that custom orthotics can fix
Custom orthotics aren't a cure-all, but for these conditions the evidence and our clinical results are strong:
- Plantar fasciitis & heel pain Offloads the heel and supports the arch so the fascia can heal
- Children's foot pain Flat feet, in-toeing, growing pains
- Shin splints A common pronation-driven injury in runners
- Lower back pain When poor foot alignment is feeding into the chain
- Metatarsalgia / ball-of-foot pain Redistributes pressure off the metatarsal heads
- Flat feet & overpronation Restores arch position to stop the chain reaction up the leg
- Knee pain from foot mechanics Particularly patellofemoral pain linked to overpronation
- Achilles tendinopathy Reduces strain on the tendon as it heals
- Bunions Slows progression and reduces pain during walking
- Sports injuries & injury prevention Especially for runners, netballers, hikers and tradies
Why 3D printed orthotics
We're the only podiatry clinic in Newcastle making custom orthotics with 3D scanning and printing. Here's why it matters:
Faster.
Traditional orthotics involve a cast going to an external lab, then waiting weeks. Our orthotics are printed locally — most patients have them fitted within 7–10 days.
More precise.
Plaster casts and foam boxes capture an approximation of your foot. A 3D scan captures it to sub-millimetre accuracy, and the printer reproduces that geometry exactly. There's less guesswork in the lab and less need for adjustments after fitting.
More durable.
3D printed polymers outlast the EVA foam and old plastics used in traditional devices. Most of our orthotics last 2–3 years of daily use before needing replacement.
Cleaner process.
No plaster, no mess, no foam goo between your toes. You sit in front of the scanner for under a minute.
More cost-effective than you'd expect.
Because we've cut out the external lab, 3D printed custom orthotics are competitively priced against traditional custom devices — sometimes cheaper.
What happens at your orthotic assessment
A first appointment runs around 30 minutes. There's no obligation — if orthotics aren't right for you, we'll say so.
1. Medical history & symptoms
We talk through your pain, when it started, what makes it worse, past injuries, footwear, work, sport, and any medications. Bring the shoes you wear most.
2. Physical examination
We assess joint range of motion, muscle strength, foot posture and any structural findings (bunions, callus patterns, leg-length differences).
3. Gait analysis
We watch you walk — and run, if relevant — to see how your foot loads, where it collapses, and where the chain is breaking.
4. 3D foot scan
You stand on our 3D scanner for a few seconds. That scan becomes the foundation of your orthotic design. No plaster, no foam.
5. Fitting & follow-up
Your orthotics are usually ready within 7–10 days. We fit them, check them in your shoes, and book a review at 4–6 weeks to make any small adjustments. There's a short break-in period — most people are wearing them all day within 2–3 weeks.
Cost, private health rebates & HICAPS
Most patients pay very little out of pocket. Here's how it works:
HICAPS on-site
We process your private health rebate at the counter — you only pay the gap.
Private health
Custom orthotics prescribed by a podiatrist are claimable through most extras policies that include podiatry. The rebate amount depends on your fund and level of cover.
Medicare CDM / EPC plans
If your GP has put you on a Chronic Disease Management plan, Medicare may cover part of your consultation cost. Bring your referral.
No GP referral required
You can book directly with us as a private patient at any time.
DVA & NDIS
We see patients under both programs — (NDIS call us to confirm your funding details).
Tip: ring your private health fund and ask "What's my rebate for podiatry consultation and for custom orthoses?" — they'll quote both numbers.
FAQ's
No. You can book directly with us. If you have a Chronic Disease Management (CDM/EPC) plan from your GP, that may contribute to the cost of your consultation, but it's not required.
With normal daily use, our 3D printed orthotics typically last 2–3 years. We recommend a review every 12 months to check fit and wear as your feet and activity levels change.
Most patients notice improvement within the first 2–4 weeks. There's a short break-in period where we recommend wearing them for increasing hours each day — about 2 hours on day one, working up to all day by the end of week two.
Yes. Orthotics are commonly prescribed for children with flat feet, in-toeing, growing pains and Sever's disease (heel pain in active kids). Children's feet grow quickly, so we review and adjust more frequently.
Not necessarily. Orthotics are often part of a broader treatment plan that includes stretching, strengthening and footwear changes. Some patients use them long-term; others find their pain resolves and they can taper off.
Costs vary depending on the complexity of your case and your private health cover. We're happy to quote during your assessment, before any work is done. Most patients with extras cover pay a relatively small gap.
Most of them, yes. They fit best in lace-up shoes, runners and boots. They can also be made in a slimmer profile for dress shoes or flats — let us know what you'll be wearing them in and we'll design accordingly.
Traditional custom orthotics are made by taking a plaster cast or foam impression of your foot and sending it to a lab. 3D printed orthotics start with a digital scan that's accurate to fractions of a millimetre, which we then print locally. They're more precise, faster to manufacture, and made from longer-lasting materials.
Where are we?
East Coast Podiatry Clinic is at 2/1 Glebe Street, Kahibah — five minutes from Charlestown Square, with off-street parking. We see patients from across Newcastle and Lake Macquarie, including:
Charlestown · Kahibah · Whitebridge · Dudley · Redhead · Belmont · Gateshead · Cardiff · Glendale · Kotara · Adamstown · Mt Hutton · Warners Bay · Newcastle CBD · Merewether · The Junction · and the wider Hunter region.
Ready to stop working around the pain?
Book a foot assessment online — most appointments are available within the same week. No referral needed.