A nano-silver footwear orthotic includes at least two removable inserts. The footwear orthotic and/or the at least two removable inserts are composed of a nano-silver copolymer being copolymer with silver nano-particles therein. In one aspect, the copolymer is a thermoplastic elastomer. The nano-silver copolymer has anti-microbial effects and ensures biocompatibility with known undesirable microorganisms. Corresponding manufacturing processes prepare the silver nano-particles with a silver nitrate solution and a sodium borohydride solution and add the silver nano-particles to a master batch and a base material to form the nano-silver copolymer in a mold cavity. The mold cavity may be constructed to form the nano-silver footwear orthotic and/or a removable insert therein. Alternatively, the nano-silver copolymer may be formed within the nano-silver footwear orthotic itself to form a removable insert. Tests showing the content of silver nano-particles in a silver--copolymer mixture and corresponding antimicrobial effect tests show antimicrobial effects against bacteria known to cause foot odor and itchiness.