The process: Actual case studies photographs
Assessment
The first critical step is a full visual assessment.
This involves a photographic and/or video recording of the lower limb problems.
Illustrated here are the angles of displacement drawn to assist in calculating corrective pieces required.


3D Foot Scanning and/or Casting
Next step is a 3D foot scan and/or plaster casting of the foot shape with the subtalar joint in neutral. This is used to highlight the angle of the midtarsal joint for computer analysis as every foot is unique.
Negative cast computer scanning
The scanning step takes away any guesswork of how the foot shape should be formed to create the corrective orthotic. Combined with powerful computer software and an imported specialised scanner, the shape is captured and digitised.


Prescription calculations
Using the digital information from the scanner combined with a skilled operator the measurements are checked and analysed for accuracy. The computer data set is confirmed specific to each customer and then sent to the cast production CNC machine.
Positive cast production with the computer CNC Machine
With the precise data from the prescription calculations the computer driven cast shaping machine precisely routs and grinds out the shape in high density MDF material.


Orthotic vacuum forming
Using the shaped high density MDF material, a silicone form is created by the application of a vacuum press in conjunction with heat. The result is a highly accurate representation of the contours required for the final orthotic piece.
Precision grinding - orthotic finishing by hand
A skilled operator is then required in the process of finishing and grinding the orthotic to it’s polished finish.


Hand crafted custom prescription orthotic
Because no two feet are the same, custom made orthotics come in all shapes and sizes.