SAOR ("s-air") is our new range of sustainable,
custom made foot orthoses.
Get SAOR
Made from PA11, a plant-based material, it’s recyclable and zero-waste: an innovation for podiatry, from the wasteful production of traditional devices.
At 7-days, and lower pricing for the standard, naked shell edition, we're improving turnaround times and pricing. 10 day turnarounds for fully finished editions will improve as we invest more in local manufacturing.
Lighter and stronger than any of our devices, the new 3D-printed material gives a finer range of rigidity-flexibility and better durability. Upholding Firefly's quality, every device is guaranteed 5 years.
Dive Deeper
FAQ
What are the turnaround times for SAOR?
9 days for naked shells, around 2 weeks for more additions. By using our FUSION scanner app, you can achieve quicker turnarounds, because your scans reach us instantly. Posted order forms make the process slightly longer.
Why choose "Naked Shell"/Standard Device?
• PA11 material is sustainable & more durable
• Faster turnaround times
• Cost effective
• Suitable for wet environments
How do I cast for 3D devices?
Using your traditional methods like plaster of paris or foamboxes, or preferably our 3D scanning app. Click here for our comprehensive guide to scanning.
Can I place an order with the AOMSTOT app?
No – the AOMSTOT app produces a 3D file type that is not compatible with Firefly’s 3DP devices as the obj file type does not provide enough detail.
How do I order 3D devices?
In the app or order form, choose your device type, then tick "3D PRINTED" shell option under the shell material section.
Can I order a repeat set?
Yes, if your previous set was 3D printed you can order a repeat set by emailing Firefly.
If the previous set was vacuum formed or milled, but you want an additional 3DP set, then you will have to scan or cast the patient again. This is considered a new order.
Can I alter the prescription 1-2 days after submitting an order?
No. Firefly’s 3D Printed devices progress into manufacture status much quicker than traditional polypropylene. While it may take up to 48hrs for a polypropylene or carbon fibre device to go into manufacture after it has been submitted to Firefly, Firefly’s 3D printed shells are processed for manufacture within hours of receipt.
A remake charge will be applied should a change of prescription be requested after manufacture has been actioned.
What can and can't be modified?
Unlike polypropylene products removing shell modifications such as lateral flanges is not possible with 3DP devices because the material can't be ground with a machine.
Does the outgrowth programme apply 3D printed devices?
Yes, Firefly will honour our Outgrowth programme for 3D printed devices.
How can I modify the devices?
PA11 cannot be heat molded, so grinding is not the same as polypropylene. We regularly refurbish devices for customers, and recommend up to 3 modifications within its 5 year life span. Continuous adjustments can alter the overall shape and width of the device over time.
Note: Modifying them yourself will void the warranty.
What 3D printing process is used to manufacture SAOR devices?
Selective Laser Sintering (SLS) is the process used to create our 3D printed shells. Sintering fuses material together to create a solid mass. A computer controlled CO2 laser draws slices of a CAD model in a bed of material fusing micron-sized particles, one layer at a time.
What does the guarantee cover?
It covers every 3D-printed material – ie the base shell, including unitised elements – for 5 years. Other materials, including top covers and additions, are not covered, as wear can vary depending on prescription and patient use.
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