Orthotic Solutions

The Manufacturing Process

Orthotic Solutions

Creating your custom orthotics is an exacting, labor-intensive procedure. Since each orthotic insert is intended to be an exact reproduction of your individual foot, it is important that knowledgeable experience, proper care and supervision be integral parts of the process. View our process below.

Foot Evaluation

  • Orthotic Solutions: Process - foot evaluation
  • Orthotic Solutions: Process - foot evaluation
  • Orthotic Solutions: Process - foot evaluation
  • Orthotic Solutions: Process - foot evaluation
  • Orthotic Solutions: Process - foot evaluation
  • Orthotic Solutions: Process - foot evaluation

Creating your custom made orthotics must begin with an initial evaluation by our Board-Certified Pedorthist. During the examination your feet will be measured, checked for arch height and given a general score.

Foot Impression

  • Orthotic Solutions: Process - foot impression
  • Orthotic Solutions: Process - foot impression
  • Orthotic Solutions: Process - foot impression
  • Orthotic Solutions: Process - foot impression
  • Orthotic Solutions: Process - foot impression
  • Orthotic Solutions: Process - foot impression
  • Orthotic Solutions: Process - foot impression
  • Orthotic Solutions: Process - foot impression
  • Orthotic Solutions: Process - foot impression

After each foot is physically inspected and measured, we then begin making a mold of your foot. By using our unique rapid impression bath, we are able to take your foot impression in approximately 60 seconds. Once completed, we create a physical reproduction of your foot by pouring a rapid drying liquid plaster in the impression.

Filing and Cleaning

  • Orthotic Solutions: Process - filing and cleaning
  • Orthotic Solutions: Process - filing and cleaning
  • Orthotic Solutions: Process - filing and cleaning

Once it is fully dried, this plaster foot is then filed down and finished to the exact proportions and details of your feet. Our orthotics will then be shaped directly from this plaster composition.

Vacuum Forming

  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming
  • Orthotic Solutions: Process - vacuum forming

After the plaster composition is completed, we apply multiple layers of temperature-sensitive plastic and/or EVA rubber material onto our vacuum former. Through the use of vacuum, the materials form precisely around the bottom half of the plaster foot. This process is repeated several times to reach the desired thickness and density for each pair of orthotics.

Trimming and Shaping

  • Orthotic Solutions: Process - trimming and shaping
  • Orthotic Solutions: Process - trimming and shaping
  • Orthotic Solutions: Process - trimming and shaping
  • Orthotic Solutions: Process - trimming and shaping
  • Orthotic Solutions: Process - trimming and shaping
  • Orthotic Solutions: Process - trimming and shaping
  • Orthotic Solutions: Process - trimming and shaping
  • Orthotic Solutions: Process - trimming and shaping
  • Orthotic Solutions: Process - trimming and shaping

This step allows us to remove all excess materials by a repeated process of cutting and grinding of each orthotic. Once all excess material have been removed, the orthotic is now ready for the shaping process. The orthotic now undergoes additional heating in order to be exactly shaped to the specific shoe (or multiple shoes). After the shaping, the orthotic is finely sanded and then fitted to the client. Since every step of the process is handled directly by our Board-Certified Pedorthist, the resulting orthotic is a faithful reproduction of the original mold.

Final Fitting

  • Orthotic Solutions: Process - final fitting
  • Orthotic Solutions: Process - final fitting
  • Orthotic Solutions: Process - final fitting
  • Orthotic Solutions: Process - final fitting
  • Orthotic Solutions: Process - final fitting
  • Orthotic Solutions: Process - final fitting
  • Orthotic Solutions: Process - final fitting
  • Orthotic Solutions: Process - final fitting

At this stage, the orthotic is then fitted into the specific shoe. The fit and function is then evaluated by both the client and our Pedorthist in order to ensure that the orthotic is capable of producing the intended result. Should any additional follow-up adjustments be necessary, these adjustments can be completed in a brief office visit, for which there is no additional charge.