Orthotics manufacturing survey

The challenge

The University of Derby commissioned Accelerate Associates to carry out a detailed assessment of the orthotics market. The study focused on the UK and North American markets, with an emphasis on emerging smart orthotic manufacturing technologies such as 3D printing.

The university sought to better understand current manufacturing methods, funding structures, key players, and clinical openness to innovation.

Our approach

Accelerate Associates designed a tailored research programme to provide strategic market insight. Our approach included:

  • Desk-based research to profile manufacturers, technologies, and orthotics market dynamics
  • Primary research with 50 senior orthotics professionals across the UK and North America
  • Online surveys and structured interviews covering clinical practice, procurement, and innovation readiness
  • Comparative analysis of UK NHS services and North American healthcare systems

Participants represented both public and private orthotics services, including clinicians, orthotists, prosthetists, and fabrication managers.

Results and insight

The research uncovered insights spanning clinical practice, innovation readiness, and the broader orthotics landscape:

Current clinical practice and manufacture

  • Traditional methods dominate segments of the orthotics market.
  • Challenges include variability in fit, especially for paediatric patients, and inconsistent fabrication quality

Smart orthotic manufacturing

  • Adoption of 3D printing remains low in some product segments; scanning and printing are more commonly applied to orthotic devices such as foot orthoses, spinal braces, and cranial helmets.

Market dynamics

  • Over 60% of NHS orthotics services are delivered by private contractors

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