CAD-CAM Orthotic Blocks & Custom EVA Foam Cutting Service

Precision EVA Solutions for Orthotic Labs and Australian Industry

Algeos Australia provides a complete custom EVA foam cutting service designed to meet the high standards of orthotic laboratories, footwear manufacturers, and industrial clients requiring accurate, durable and performance-driven foam components. Using advanced CAD-CAM technology, we supply EVA orthotic blocks and custom-cut foam in various densities, colours, thicknesses and shapes, tailored precisely to your specifications.

What Is EVA Foam?

EVA (Ethylene Vinyl Acetate) foam is one of the most versatile and reliable materials used across healthcare and manufacturing. It combines softness, shock absorption and durability, making it an ideal choice for orthotic devices, padding systems, protective equipment and footwear components. In orthotics, EVA foam provides the perfect balance between cushioning and structural support, helping clinicians and technicians deliver accurate and comfortable patient outcomes.

Tailored EVA Foam Cutting for Orthotic Labs

Every orthotic design is unique, and precision cutting is vital for consistent results. Our custom EVA cutting service is designed specifically for orthotic labs in Australia that demand accuracy, repeatability and material integrity. Each order is cut to your exact design dimensions using advanced die-cutting and milling technology, ensuring tight tolerances and minimal material waste. Whether you require full orthotic blanks, forefoot inserts, heel wedges or metatarsal pads, Algeos ensures every piece fits seamlessly into your workflow.

Custom EVA Densities for Clinical Performance

We offer a broad range of EVA densities to match different functional and biomechanical requirements:

• Low-Density EVA: Soft and flexible, ideal for top covers, cushioning layers and pressure relief zones.
• Medium-Density EVA: Balances comfort and resilience — perfect for general-purpose orthotic devices and footwear midsoles.
• High-Density EVA: Provides firm support and structural integrity for load-bearing areas or corrective orthotic designs.

Density directly affects performance. For example, higher densities are better for stabilising flat feet or supporting heavier patients, while lower densities improve comfort in diabetic or sensitive-foot applications. With multiple density options available, you can tailor orthotic function precisely to each patient’s needs.

Wide Range of Colours for Identification and Branding

Algeos supplies EVA foam in multiple colour options to support visual identification and brand consistency. Orthotic labs often use colour coding to distinguish between densities or layers during fabrication. Similarly, footwear manufacturers can match brand colours or highlight product lines. Our coloured EVA sheets and blocks help streamline workflow and give your finished products a professional, cohesive appearance.

Precision Thicknesses for Consistent Results

Thickness control is critical for orthotic performance and comfort. Algeos offers custom EVA sheets and blocks in a range of thicknesses, precisely cut using calibrated machinery to maintain consistent dimensions across batches. Thicker foams deliver increased cushioning and shock absorption, while thinner foams provide flexibility and a lower profile ideal for in-shoe orthoses or lightweight footwear designs. Every sheet is machined to tight tolerances to reduce post-processing time and ensure consistency from the first pair to the last.

Advanced Shape Cutting with CAD-CAM and Die-Cutting Technology

Our state-of-the-art CAD-CAM cutting and die-cutting systems enable us to produce virtually any EVA foam shape - from complex orthotic geometries to industrial inserts and sporting components. We can process digital design files directly from your orthotic CAD system, ensuring an exact replication of your model with no loss of accuracy. Whether producing a single prototype or large production runs, our cutting process guarantees clean edges, repeatable detail and efficient turnaround times.

Industries That Benefit from Our Custom EVA Cutting Service

• Orthotic Laboratories: Precision-cut blanks, blocks and top covers ready for finishing or lamination.
• Footwear Manufacturers: Custom midsoles, insoles and impact-absorbing components in branded colours.
• Sports & Protective Equipment: EVA padding for helmets, guards and shock-absorbing inserts.
• Automotive & Industrial Applications: Vibration-damping foam parts, insulation and comfort panels.

Our flexibility makes Algeos Australia a preferred partner across medical, commercial and industrial sectors.

Why Choose Algeos Australia?

• Precision Manufacturing: CAD-CAM and die-cutting technology ensures accuracy and repeatability at scale.
• Local Expertise: We’ve supported Australian orthotic and footwear industries for decades with technical advice and dependable supply chains.
• Customisation Options: Choose your preferred foam density, colour, shape and thickness to match your exact needs.
• Sustainability Focus: Optimised cutting patterns and waste reduction improve material yield and minimise environmental impact.
• Rapid Turnaround: Local processing and inventory mean faster delivery for urgent orders and repeat customers.

Applications of Custom EVA Foam Cutting

Our custom-cut EVA foam supports a variety of practical uses, including:

• Orthotic insoles, heel lifts, wedges and arch supports
• Therapeutic and diabetic footwear components
• Protective padding for sports and occupational applications
• Foam inserts for automotive interiors and packaging solutions

Each component is designed to balance comfort, support and durability — critical factors in high-performance, patient-focused and commercial environments.

Partner with Algeos for Custom EVA Cutting

Algeos Australia is committed to supporting your business with tailored EVA foam cutting solutions that match your exact requirements. Our CAD-CAM orthotic blocks and custom-cut EVA sheets are engineered for performance and precision, ensuring that every project, from individual orthoses to large-scale production, meets the highest standards.

Contact our technical team to discuss your design files, foam specifications or volume needs. We’ll help you select the ideal EVA density, colour and thickness to suit your application - and provide a quotation with clear lead times and delivery options.