Formthotics New Zealand – Custom Thermoformable Medical Orthotic Insoles - Our Story

Where It All Began

It all started with a simple observation in the sand. Our feet were never meant to cope with the hard, flat, and unforgiving surfaces that define modern life. In the 1970s, in New Zealand—a country known for adventure and innovation—two pioneers came together to solve a problem that affects us all: how to restore the natural movement and support our feet were designed for.

The Beginnings of Formthotics

Dr. Charlie Baycroft, a sports medicine specialist, realised that replicating the soft support of sand could help people suffering from foot pain, injuries, and discomfort. At the same time, professional skier, boot-fitter, and now Director of Foot Science International (the parent company of Formthotics), David Boyd, was exploring how custom orthotics could improve his skiing performance. Through research, he developed early prototypes using thermoplastic foam that could mould to the foot. A chance encounter between Dr. Baycroft and David Boyd sparked a 30-year partnership, resulting in the first version of Formthotics—custom orthotics designed to restore natural foot function and keep people active.

Innovating for Better Movement and Health

Today, we carry forward their legacy by constantly innovating and improving our products to meet the diverse needs of both patients and athletes. From clinical applications to sports performance, the passion for improving lives remains the driving force behind everything we do.

"We exist to make a difference, helping prevent and treat injuries while improving lives by keeping people healthy, active, and mobile."

This purpose is at the heart of everything we do —whether through supporting clinicians in treating foot conditions or helping athletes achieve peak performance. Our custom orthotics are designed to empower people to move freely, comfortably, and confidently every day. This commitment has opened up new opportunities, enabling our business to grow while increasing our positive impact on the planet and people. It drives us to constantly innovate, striving to create the highest quality products.

"The desire to develop and improve products to keep people active and mobile is one of the few things that hasn’t changed over the years." --- David Boyd, Founder of Formthotics

David Boyd, Founder and Director

An avid skier, David recognized the potential for custom orthotics to enhance performance and comfort for athletes, leading to the creation of Foot Science International. With expertise in manufacturing, medical devices, and international business, David continues to shape strategy as Director of several successful companies. You can still find him at headquarters in Christchurch, staying deeply involved with Formthotics’ future.

Shane Heenan, CEO

A problem-solver with emotional intelligence, Shane combines strategic thinking with a passion for people. With over a decade of experience in technology and international markets, he drives revenue growth while building a human-centred culture. Whether leading the business or flipping BBQ steaks, Shane believes in one thing: “There are plenty of things you can fake in life. Passion isn’t one of them.”

Jarrod Patrick, Sales Director

Jarrod brings over 15 years of international sales and marketing experience, building relationships and expanding the Formthotics brand into new markets. He supports key account managers while forging new opportunities across both medical and retail segments. When not growing business, you’ll find Jarrod restoring vintage motorcycles or trying his hand at cattle farming.

Steve Lafferty, Business Development Manager, Asia Pacific

With a Sports Science degree and a love for biomechanics, Steve explores new market opportunities across the Asia Pacific and Middle East. He fosters partnerships with distributors and universities and leads workshops for clinicians worldwide. When not working with feet, Steve enjoys sailing classic yachts around Auckland’s Hauraki Gulf.

Anna Coope, European Account and Education Manager

Anna brings over two decades of experience in account management, healthcare, and podiatry. Her expertise in lower-limb pathology and attention to detail make her the ideal lead for developing our education platform. On weekends, you’ll find Anna re-upholstering furniture or tending to her garden in her 1930s home.

Dr. Bob Eckles, Medical Director

A podiatrist with a lifelong passion for biomechanics, Dr. Eckles’ journey began in the late ’70s after an injured foot inspired him to pursue podiatry. He has held roles ranging from foot surgeon in California to Associate Dean at the New York College of Podiatric Medicine. Today, Dr. Eckles is thrilled to be advancing foot and leg mechanics with Formthotics, advocating for the expertise podiatrists bring to wound care, surgery, and sports medicine.