After your face-to-face assessment, all necessary scans, measurements, and castings are submitted to our UK-based manufacturing teams. We operate across three specialist sites: Wellingborough, Aldershot, and Lewes. Our Wellingborough and Aldershot centres primarily produce bespoke orthotic products for Halo Medical, while our Lewes facility focuses on paediatric orthoses for Florence. Depending on the complexity of the item, different parts may be completed across more than one site to ensure the best result.
What to Expect During Manufacturing
Once your orthosis order is submitted by your orthotist, it is reviewed by our planning team, who determine the technical requirements and timeline. From there, it moves to our design specialists who refine every detail, ensuring the product meets both clinical and functional needs. Whether your device is simple or highly customised, this step ensures precision before production begins.
The finalised design is passed to our skilled manufacturing technicians. Every orthosis is crafted with care, and during production, quality assurance checks are performed at each stage to ensure a perfect fit and high durability. Our Florence orthoses often include personalised details to make them feel more friendly and appealing to children and young people—small touches that help every orthosis feel unique.
Once complete, your orthosis is sent to the clinic where your fitting appointment is scheduled. Most devices are ready within two weeks, although more complex items like bespoke footwear may take slightly longer. Your orthotist will explain the expected timeframe at your assessment, so you know exactly what to expect and when to return for fitting.
Our in-house collaboration between clinicians and technicians ensures fast, accurate turnarounds, with a strong focus on quality at every step. This integration allows us to quickly respond to any necessary adjustments, streamlining the entire process from design to delivery.
Our facilities are equipped not only for production but also for modification, so if any final tweaks are needed during your fitting, they can be completed on-site—saving you time and ensuring the best outcome before you leave the clinic.