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How Custom Orthotics Are Made

how custom orthotics are made for foot pain and conditions active alignment

Custom orthotics can be life-changing for those dealing with foot pain, improper alignment, or other biomechanical issues. But have you ever wondered how these seemingly simple devices are meticulously crafted to fit your feet? Pedorthists are specialists in custom orthotics, merging medical expertise with precise craftsmanship to create these solutions. Here’s a closer look at how they do it.

Step 1: Understanding the Patient’s Needs

gait analysis biomechanical assessment custom orthoticsThe process begins with a thorough assessment of the patient’s foot health, lifestyle, and specific concerns. During this phase, the Pedorthist will:

  • Conduct a medical history review: This helps identify any underlying conditions like plantar fasciitis, flat feet, or arthritis.
  • Conduct a hands-on biomechanical assessment: Physically comparing joint positions and joint integrity, ranges of motion (not enough or too much), muscle strength/weakness, palpation of anatomical landmarking and measurement such as leg length and hip/pelvis position.
  • Perform a gait analysis: Observing how you walk reveals patterns of movement and alignment issues.
  • Examine your footwear: Pedorthists assess the type, fit, and wear patterns of your shoes to understand their role in your discomfort.

Step 2: Creating a 3D Foot Impression

make foot impression in foam box for custom orthoticsNext, the Pedorthist creates a detailed model of your feet. This step ensures that the orthotics fit perfectly and address your unique needs. The process can include:

  • Casting with plaster wrap or foam box: The tried-and-true, traditional method where the foot is placed in a foam box or a plaster mold. This method yields reliable results and is generally preferred.
  • 3D scanning: A high-tech option that captures a digital image of the foot for precise measurements and contours. There can be limitations to this method so is used only periodically.

We are skilled in all methods, but selection all depends on each individual’s patient needs!

Step 3: Designing the Orthotic

Using the foot model, the Pedorthist designs the orthotic to support, cushion, or correct specific areas. Factors considered during this stage include:

  • The type of activity (e.g., running, standing for long hours).
  • The level of arch support needed.
  • Any specific corrections required for alignment issues or pressure relief.

Step 4: Fabrication

how custom orthotics are made for foot pain and conditions active alignmentOnce the design is finalized, the orthotic is crafted using durable and flexible materials. This involves:

  1. Milling or molding the base: The main structure of the orthotic is formed using materials like EVA foam, Aliplast XPE, or ultra thin Subortholen or polypropylene.
  2. Adding layers for comfort: Cushioning materials, such as memory foam (poron or neoprene) are added and layered based on the patient’s needs.
  3. Shaping and finishing: The orthotic is cut, shaped, and polished to fit seamlessly into the patient’s footwear.

Step 5: Fitting and Adjustments

After fabrication, the Pedorthist schedules a fitting appointment to ensure the orthotics fit correctly and feel comfortable. This step may involve:

  • Testing the orthotics in different shoes.
  • Making minor adjustments for better alignment or pressure relief.
  • Educating the patient on how to break in the orthotics gradually.

Step 6: Follow-Up Care

Over time, your foot shape or condition might change, requiring adjustments or replacements. In addition, orthotics will compress with long-term use. To ensure continued effectiveness, Pedorthists recommend regular follow-ups.

Why Choose a Pedorthist?

Pedorthists are trained professionals with the expertise to address complex foot mechanics. Their attention to detail and personalized approach ensure that your orthotics don’t just fit but actively improve your quality of life.

Whether you’re dealing with chronic pain or looking for enhanced comfort, visiting a Pedorthist for custom orthotics can make all the difference. Take that first step toward healthier, happier feet!

Do you use custom orthotics? Share your experiences or questions in the comments below!