±0.1mm
Layer Accuracy
PA11
Nylon Material
100%
Solar Powered
<5 Day
Turnaround
Selective Laser Sintering
We use a Formlabs Fuse 1+ SLS printer — the gold standard in professional 3D printing. SLS (Selective Laser Sintering) works by spreading a thin layer of nylon powder across a build platform, then using a precision laser to fuse the powder particle by particle, layer by layer.
Each layer is just 0.1mm thick, building up a fully solid, isotropic part with no weak points or layer lines. Unlike traditional vacuum forming or milling, SLS produces orthotics with consistent mechanical properties throughout the entire device.
Why SLS is Superior
- ±0.1mm accuracy — faithfully reproduces the exact geometry prescribed
- Isotropic strength — equal strength in all directions, unlike FDM or milled devices
- Complex geometries — no tooling constraints, enabling designs impossible with traditional methods
- Repeatable precision — identical results every time, batch after batch
PA11 Bio-Based Nylon
Every Réalta orthotic is printed in PA11 — a high-performance, bio-based nylon derived from castor beans. PA11 delivers an exceptional combination of strength, flexibility, and biocompatibility that far surpasses traditional polypropylene.
Material Properties
- High fatigue resistance — maintains performance through thousands of loading cycles
- Excellent flexibility — controlled deflection for dynamic foot function
- Biocompatible — safe for prolonged skin contact, hypoallergenic
- Sustainable origin — derived from castor beans, a renewable resource
PA11 vs Polypropylene
Traditional polypropylene orthotics are formed under heat and pressure, which introduces internal stresses and inconsistent thickness. PA11 printed via SLS has uniform density throughout, superior fatigue life, and can be engineered with variable thickness zones for optimised biomechanical performance.
Solar-Powered Production
Our entire production facility is powered by 100% solar energy. From the Fuse 1+ printer to the post-processing stations, every stage of manufacturing runs on renewable energy. Combined with our bio-based PA11 nylon, Réalta Labs is committed to delivering zero-carbon orthotics without compromising on quality.
Sustainability isn't an afterthought — it's built into every device we produce.
