With over a century of experience and a dedicated facility in Lancashire, our custom fabrication department is equipped to design and manufacture the exact brace needed for each unique patient. Beagle Custom Fabrication was established to address more complex orthopaedic conditions, with a singular goal: restoring mobility, independence, and quality of life for patients.
At Beagle, we understand that mobility means different things to different people, and we utilise every available resource to make it a reality. Our Custom Fabrication division proudly manufactures bespoke devices in the UK, offering solutions for complex cases. In addition to our extensive range of custom-made devices such as AFOs, KAFOs, and insoles, we specialise in advanced innovations—particularly in spinal and hip bracing. This includes the seamless integration of stock products into custom devices like CTLSOs.
Since our expansion into custom fabrication in 2010, led by Technical Director Andy Dewsbury and Production Manager Liam Penny – who together bring over 55 years of orthotic fabrication experience – we’ve built a reputation for exceptional customer service and unparalleled craftsmanship.
Our commitment to delivering high-quality stock and bespoke products has been further enhanced by our ability to offer custom solutions for more complex conditions, positioning us as a comprehensive, one-stop supplier for customers seeking tailored orthoses.
People remain at the heart of our custom manufacturing process. The specialised skills our team brings to each project are essential to creating precise, patient-specific devices. While many traditional techniques, such as handcrafting, have stood the test of time, we also embrace new technologies to push the boundaries of what’s possible. Our Qwadra scanner service, for example, eliminates the need for traditional casting, allowing for more accurate adjustments through advanced shape manipulation software, resulting in a truly custom fit.
In addition to offering a wide range of traditional orthoses, such as AFOs and insoles, we’re committed to developing forward-thinking, innovative solutions. Our expertise particularly excels in spinal and hip bracing, where we blend stock and custom elements to meet the most complex requirements.
Expanding into custom orthotics has allowed us to adopt a strategic approach that sets us apart from the competition. By collaborating closely with clinical teams, we aim to create protocols that not only reduce costs but also improve the efficiency and quality of existing services—ensuring better outcomes for patients and stronger partnerships with our customers.
The unique design enables the wearer to freely move the head and waist from side to side, whilst fully supporting the head and upper cervical/thoracic region.
See the World in a new dimension!
Crafted by skilled technicians with years of expertise, our cosmetic KAFOs are meticulously designed to meet a variety of needs. We specialise in manufacturing conventional metal and leather Ring, Bucket, and Corset Tops, as well as innovative Hybrid and Full Cosmetic Designs.
Collecting accurate patient information is essential, which is why we provide a ‘Service Visit’ during the initial consultation to ensure all technical details are thoroughly agreed upon and documented. Depending on the patient’s pathology and presentation, we can also utilise our 3D scanner to capture precise measurements of the KAFOs.
Our skilled technicians can create any style of AFO tailored to your needs. We offer a diverse range of options, including custom-fabricated, solid, semi-rigid, articulated, and night splint designs, as well as patella tendon-bearing models. Additionally, we provide a variety of ankle hinges, pads, straps, and transfer patterns that both children and adults appreciate.
Custom spinal brace engineered to deliver optimal support for high thoracic control, making it ideal for managing complex, multi-level spinal conditions. It is indicated for spinal injuries and conditions ranging from C1 to L5, providing comprehensive stabilisation and protection across the cervical, thoracic, and lumbar regions.
Clinicians seeking a long-term solution or a “belt & braces” approach, we offer a Full Custom CTLSO. This option provides optimal control in both the coronal and sagittal planes, ensuring comprehensive stabilization throughout the entire spinal column. Each brace is meticulously crafted to a series of precise measurements and is manufactured within 3 to 5 working days, delivering both precision and reliability.
Custom-designed cervical-thoracolumbosacral orthosis (CTLSO) that offers superior support for high thoracic control. This brace is ideal for managing multi-level spinal conditions, including injuries spanning from C1 to L5, ensuring comprehensive stability across the cervical, thoracic, lumbar, and sacral regions.
At Beagle Orthopaedic Custom Fabrication Division, we believe that people are invaluable in the process of manufacturing custom orthopaedic devices. The unique skills required for this work are critical, and we take immense pride in our team’s expertise, craftsmanship, and dedication to delivering precise, patient-specific products.
Many of the traditional manufacturing techniques we use have remained unchanged over the years. Hand craftsmanship is still central to the way we create our custom devices, ensuring a level of care and precision that only skilled artisans can provide. However, as technology evolves, we also embrace innovation to enhance our capabilities. Our use of the Structure Sensor Scanner & I Pad is one such example, where innovative technology complements traditional methods.
The Qwadra system revolutionises the custom fabrication process by eliminating the need for physical casts. Using advanced shape manipulation software, precise alterations can be made digitally, allowing for an exact custom fit that perfectly suits the patient’s needs. The scanner captures detailed 3D measurements of the body, and the software can modify the digital model, providing a highly accurate orthosis or prosthetic design.
Structure Sensor Scanner & iPad uses Captvia Data Capture App that integrates seamlessly with the Qwadra NEO software, which is compatible with. These tools ensure smooth collaboration between digital scanning and our traditional craftsmanship, helping us create truly custom devices with unmatched accuracy and efficiency.
By blending human skill with modern technology, Beagle Custom Fabrication continues to set new standards in orthopaedic device manufacturing, ensuring that every product is tailored specifically for individual patient needs.
All of our custom products feature downloadable Orthometry Charts, which can be printed and filled out by hand or edited online for your convenience. Just complete the required details and send them back to us for fast and efficient processing.
Explore our Transfer Pattern Swatch for AFO and KAFO products, whether you’re looking for a design that appeals to children or adults, our swatches ensure that each brace not only provides exceptional support but also looks great.
