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FSA/HSA Eligible Orthotic Insoles – Custom Medical Grade - Bilt Labs
FSA/HSA Eligible Orthotic Insoles – Custom Medical Grade - Bilt Labs
FSA/HSA Eligible Orthotic Insoles – Custom Medical Grade - Bilt Labs
FSA/HSA Eligible Orthotic Insoles – Custom Medical Grade - Bilt Labs
FSA/HSA Eligible Orthotic Insoles – Custom Medical Grade - Bilt Labs
FSA/HSA Eligible Orthotic Insoles – Custom Medical Grade - Bilt Labs
FSA/HSA Eligible Orthotic Insoles – Custom Medical Grade - Bilt Labs

Custom Orthotics & Insoles – Medical Grade Shoe Inserts

Bilt Labs is Eligible
31,500 Analyzed
Targeted Correction

Select Your Pain Select Your Pain or Condition

Medically Engineered to treat the following:

Heel Pain Plantar Fasciitis
Arch Pain Flat Feet / High Arches
Alignment Overpronation • Supination
Ball of Foot Metatarsalgia
Burning / Tingling Morton's Neuroma
Big Toe Bunions
Achilles Tendonitis
Complex Multiple Issues
Heel Spurs Bone Spurs
View More Conditions
Disclaimer: Informational use only. Not medical advice/diagnosis. Consult a professional.
Find Your Fit
Step 1: Severity Check

Analyzing Symptoms

(Select all that apply)

Have a different foot condition/pain?
Live Houston Lab Intake
High Volume
Daily mold capacity is 88% Full. Order your kit today. The sooner your mold returns, the sooner production begins.
Dr. William Naughton
Dr. William Naughton, DPM
Board Certified Chief Medical Officer - NPI: 1245247089
Easy, At-Home Process and No Rx Needed
Includes Personalized Build Printout of your specific modifications.
Lifetime Shell Warranty and FSA/HSA Eligible
Priority Shipping and Made in USA
SAVE 50%+
Medical-Grade Orthotics Cost
$600 At A Clinic
$285 Bilt Labs Direct

Custom Orthotic Insoles:

 

Ultimate Custom Relief: Our therapeutic, custom orthotics are precision-engineered to address all common foot conditions, starting with your unique biomechanics. These are not simply generic insoles; each device is custom-made from a precise mold of your feet to correct the underlying mechanical faults that contribute to chronic pain, and come with a Bilt Labs warranty and guarantee.

Precision Correction

The key to resolving chronic foot, ankle, and knee pain is controlling excessive foot motion. Our semi-rigid design stabilizes the midfoot and hindfoot, offering targeted control over issues like excessive pronation (flat feet) and supination (high arches). By ensuring proper foot alignment, our custom orthotics stabilize your entire kinetic chain.

Unparalleled Performance 

Built from your unique foot mold and detailed health information, we guarantee a truly precise fit that mass-produced supports cannot match. Choosing Bilt Labs is choosing a durable, evidence-based therapy that offers reliable support and improves gait alignment for long-term comfort and mobility. Backed by our lifetime shell warranty.

Back to home page.

Choose Your Comfort Layer

  • Everyday (Memory Foam): Ideal for maximum cushion and all-day standing or walking.
  • Active (High Rebound): Engineered for high-performance use, providing superior shock absorption and energy return for fitness and long work shifts.
Proven Results

100,000+ Feet
Stabilized

Stop the pain and progression of bunions. Our medical-grade custom orthotics provide the essential alignment and pronation control needed to offload the big toe joint.

Find Your Fit
Save 50% vs. Traditional Clinics
BBB FSA Judge.me Optum

Easy, At-Home Process

No Rx Needed

FSA/HSA Eligible
USA Made
6-Month Guarantee
Understanding The Condition

What are Bunions?

The Pathomechanics of Joint Drift

A Bunion (Hallux Valgus) is not just a bump; it is a dislocation of the big toe joint (1st MPJ). While footwear plays a role, the root cause is often biomechanical instability, specifically overpronation.

When the foot rolls inward (pronation) excessively, it unlocks the midfoot and puts abnormal pressure on the side of the big toe. Over time, this force pushes the big toe toward the second toe, causing the joint to bulge outward and become inflamed.

Common Symptoms:

  • A bony bump on the side of the big toe joint.
  • Redness, swelling, and soreness around the joint.
  • The big toe turning inward toward the other toes.
  • Pain when wearing shoes or walking.

Fast Facts

  • Prevalence: Affects 1 in 3 adults, more common in women.
  • Risk: Heredity and flat feet are major risk factors.
  • Correction: Orthotics can slow or stop progression without surgery.

Recommended Solution:

Find Your Fit
Background

Treating the Root Cause of Bunions Pain

The Problem

Instability & Crowding

Generic insoles are often too bulky, crowding the toe box and increasing pain. More importantly, they fail to stop the pronation that causes the bunion to deviate further.

Result: Increased pain and continued joint deformity.
The Bilt Solution

Neutral Alignment

We custom-mill your orthotic to your exact arch profile. This "locks" the foot in neutral, removing the pressure from the big toe joint without taking up excess room in your shoe.

Low Profile
Control Pronation
Offload Joint
Bilt Labs Value Stack

Why Choose Bilt Labs?

Traditional

Podiatrist

  • Cost $400 - $800+
  • Lifespan 1-2 Years
  • Visit Req. Yes
  • Support Corrective
  • Guarantee Rarely
BEST VALUE
The Smart Choice

Bilt Labs

  • Cost $285
  • Lifespan 2-3 Years
  • Visit Req. No (At Home)
  • Support Medical Grade
  • Guarantee 6 Months
Find Your Fit
Drugstore

OTC Insoles

  • Cost $20 - $60
  • Lifespan 3-6 Months
  • Visit Req. No
  • Support Minimal
  • Guarantee None
The Process

Clinical Relief from Home

Professional-grade orthotics without the doctor's visit. Here is how we do it:

Order Kit
1
Order Your Kit

Start with a free analysis and order your custom impression kit.

Mold Feet
2
Mold Your Feet

Use our custom kit to take a detailed mold of your feet at home and send it back to the lab.

We Build
3
We Build & Ship

Your custom insoles are approved by a DPM, precision-milled in the USA, and delivered to your home.

Medical Expertise

Elevate your foot health with Bilt Labs today.

Experience professional-grade biomechanical correction designed to meet your immediate pain relief and long-term structural health needs – accessible directly from home.

  • Board Certified Oversight

    Every pair is reviewed by experts, ensuring clinical accuracy.

  • 30+ Years Experience

    Dr. William Naughton, DPM brings decades of orthotics expertise.

  • Medical-Grade Materials

    We use the same high-performance polymers as top podiatry clinics.

Meet Dr. William Naughton →
Medical Expert
Verified Credential

License: DPM00321
NPI: 1245247089

Chief Medical Officer

Dr. William Naughton
Board Certified Podiatrist

Precision Engineered & Hand Finished—All In the USA

  • Aerospace-Grade Materials

    We use high-performance polymers and EVA foams designed for maximum durability, shock absorption, and comfort.

  • Laser-Precision Milling

    Your orthotics are carved from a solid block of material using CNC robotics, ensuring 100% accuracy to your foot mold.

  • Hand-Crafted Quality

    Every pair is hand-finished and inspected by our technicians in our US-based lab to ensure clinical efficacy.

Start your order →

Ready for Pain-Free Living?

Order your custom impression kit today and take the first step towards lasting relief.

Find Your Fit

Frequently Asked Questions

Bunions Relief

Can orthotics cure bunions?
Orthotics cannot reverse a bunion deformity once the bone has shifted, as that is a structural change. However, they are highly effective at stopping the progression of the bunion and relieving pain by correcting the overpronation that causes the big toe to drift.
Will these fit if I have a wide bunion?
Yes. One of the biggest issues with generic insoles is that they take up too much room in the toe box, crowding the bunion. Bilt Labs custom orthotics are milled to be low-profile and typically stop just behind the metatarsal heads (3/4 length), leaving plenty of room for your toes and the bunion itself.
Do I need surgery?
Surgery is often considered a last resort due to long recovery times. Most podiatrists recommend trying conservative treatment first. Custom orthotics are the gold standard for conservative care because they address the root mechanical cause of the bunion, often providing enough relief to avoid or delay surgery.

Disclaimer: While orthotics can stop progression and relieve pain, they cannot reverse existing bone deformity. Always consult your physician regarding surgical decisions.

Product & Service

How long does it take to receive my custom orthotics?
Once you place your order, we ship out your foot mold impression kit within 1-2 business days. After we receive your molds back at our lab, we design, build, and ship your custom orthotics within 21 business days.
Are these truly custom, medical-grade orthotics?
Yes. These are not "heat-moldable" or "shelf" insoles. They are custom-fabricated from a physical mold of your foot using the same medical-grade polymers and EVA foams we supply to podiatry clinics. Nothing is pre-made or off-the-shelf.
Do you take insurance or FSA/HSA?
We are approved and set up to accept insurance FSA/HSA cards directly at checkout. We can also send a detailed invoice for reimbursement. However, we do not bill insurance companies directly as that typically requires an in-person office visit.
How long will my custom orthotics last?
Bilt Labs custom orthotics typically last a minimum of 2-3 years. The orthotic shell itself often lasts longer (and has a lifetime warranty against breaking), but the top covers may show wear and can be refurbished.
What is your return/refund policy?
We offer a full 6-month trial period. If you are not fully happy with your orthotics by that time, you can return them for a full refund. We also offer 2 free adjustments during this period to ensure the fit is perfect.
Where are my orthotics made?
Your new custom orthotics are made in the United States. We are located in the Houston, Texas area. All fabrications, designs, and finishing are performed by experts right here in our Houston lab.
What is your warranty/guarantee policy?
Your orthotics include a Lifetime Warranty on the plastic orthotic shell against breaking or cracking. This does not include the top cover material, as that is a consumable item that naturally wears with use.

See what our customers have to say.

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