In the realm of foot health and comfort, custom orthotics play a pivotal role. These specialized devices are tailor-made to fit the unique contours of an individual’s feet, providing targeted support and alleviating discomfort. The need for custom orthotics arises from the fact that every person’s feet are distinct, with variations in arch height, foot shape, and specific pressure points. Off-the-shelf insoles often fail to address these individual differences, leading to inadequate support and potential exacerbation of foot-related issues.

Custom orthotics are particularly beneficial for those suffering from foot conditions such as plantar fasciitis, flat feet, high arches, or other biomechanical abnormalities. They help in redistributing pressure evenly across the foot, correcting alignment issues, and providing a stable foundation for the entire body. This personalized approach not only enhances comfort but also prevents further complications and improves overall foot function.

The process of creating custom orthotics involves a detailed assessment of the individual’s feet, gait analysis, and precise measurements to ensure a perfect fit. This personalized attention to detail is what sets custom orthotics apart from generic solutions, making them an invaluable tool in the pursuit of optimal foot health and comfort.

Method 1: Foam Impression Box


  1. Prepare the Patient: Have the patient sit on the front edge of a chair, ensuring they are seated at a 90-degree angle with their shoes removed.
  2. Place the Foot: Open the foam impression box and place the patient’s first foot onto the foam, ensuring the foot is centered.
  3. Apply Pressure: With the foot centered, apply pressure to the top of the knee and the dorsum of the foot, pushing the foot into the foam. Then, use your fingers to press down the patient’s toes so the heel and metatarsal heads are level.
  4. Repeat for the Other Foot: Carefully remove the patient’s foot and repeat steps 2-3 for the other foot.
  5. Inspect the Impressions: Check the impressions of both feet to ensure proper depth. If there are any special requirements, inform us when ordering custom orthotics.
  6. Complete the Order Form: Fill out the custom footwear or insole order form with any additional information. Courier the foam box back to our address.

Method 2: Heat Moulding Orthotics EVA


  1. Prepare the Orthotic: Attach any forefoot or rearfoot additions prior to heat moulding.
  2. Heat the Orthotic: Using a heat gun, heat the orthotic by holding it at the distal edge, 15cm from the plantar surface, for 10-15 seconds. The words ‘left’ and ‘right’ act

    as a heat indicator; when they start to melt and flatten, enough heat has been applied. Overheating is not recommended.

  3. Place in Shoe: Insert the heated orthotic into the patient’s shoe. The patient must wear both left and right orthotics and shoes during the moulding process.
  4. Moulding: As the patient stands with equal weight bearing, place the foot into the subtalar neutral position and cup the medial arch and heel with the palm of your hand, applying pressure for 30-40 seconds to ensure the orthotic moulds to the patient’s arch.
  5. Cooling: While still holding the foot in a neutral position, have the patient sit down, remove the moulded orthotic from the shoe, and allow it to cool for 1-2 minutes before placing it back into the shoe.
  6. Repeat for the Other Foot: Repeat the process for the other foot.
  7. Attach Additions: After heat moulding, attach any required heel lifts, metatarsal domes, medial arch infills, flanges, or inversion/eversion ramps.


  • It is NOT recommended to apply heat to the Taibrelle cover on the dorsal surface.

Comparative Analysis


  • Both methods aim to provide patients with custom-made orthotic insoles to meet their individual needs.


  • Process: The first method involves creating a foot impression in foam and then making the orthotic based on that impression, while the second method directly moulds the orthotic to the patient’s foot using heat.
  • Time Efficiency: The heat moulding method is relatively faster as it eliminates the steps of making and sending a foam impression.
  • Accuracy: The foam impression method might offer a higher level of accuracy in capturing the shape of the foot, as it is made directly from the foot’s impression.
  • Comfort: The heat moulding method can provide orthotics that better fit the patient’s foot, potentially offering better comfort and support.

Advantages and Disadvantages:

  • The advantage of the first method is its potential for higher accuracy, but the process is slower and requires additional steps, such as sending the foam impression.
  • The advantage of the second method is its speed and convenience, as well as the ability to adjust the orthotic immediately to better fit the patient’s foot. However, this method might be slightly less accurate in terms of capturing the exact foot shape.

Overall, if the priority is high customization and accuracy, the first method might be more suitable; whereas if the priority is speed, convenience, and immediate comfort, the second heat moulding method might be a better choice.

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