How Are Orthotics Made?
Premier’s Orthotic Process – The Building of a Great Orthotic
In order for POL to supply you with a truly custom product, we first receive a foam or plaster cast impression of your foot corrected in sub-talar neutral.
Once your cast impression is received, we start our Quality Control process.
Your order and the selected materials and choice of correction as well as shoe selections is confirmed by our dedicated and highly competent customer service team.
Measurements of the cast are taken and marks are placed on the negative cast impression to indicate bony prominences such as 1st met head and 5th met head, navicular and sulcus line. The Calcaneous is marked for mid line vertical and then a plaster positive mould is made from the negative cast.
Process of pouring liquid plaster into plaster and foam negatives to make a plaster positive.
Once the plaster is cured, the negative mould is broken away and discarded. The markings on the negative cast impression transfer onto the new plaster positive.
The rear foot and fore foot are corrected to lab evaluation or otherwise instructed via the prescription form (Rx form).
Once the plaster positive is corrected another Quality check is performed including a complete evaluation of the cast dressing, rear foot alignment, forefoot alignment in plane with the rearfoot and amount of tissue expansion necessary.
The Rx form will indicate which types of materials to use in the fabrication process and any other special instructions.
The shell material selected will be heated and then vacuum moulded following specific standards used at POL based on the material, its thickness and overall desired effect of support required by the patient.
The shell is shaped using various grinders and buffers
After the shells are ground, a third Quality check is performed. The choice of material, the length of the shell, width of the shell, the intrinsic and extrinsic posting of the shell, any shell modifications and fitment into desired footwear are evaluated.
The orthotic is evaluated on its cosmesis, functionality, performance, prescription order and all paper work, including labels.
The order proceeds to the shipping department to be packaged on its way to the prescribing practitioner with any other product or materials requested.
We back our product and offer excellent support for fitting and adjusting.
Custom made orthotics that last! Your customers will be impressed.
Our customers are the backbone of our business. We make sure you are cared for.