1. The Orthotic Manufacturing Process

2. Hand-plaster poured and manufactured the old-fashioned way.

3. Foam Impression or Plaster cast in sub-talar neutral position is received by the Lab

4. Step 1 – Quality-control process initiated. Order is entered into system and measurements are cross-checked.

5. Step 2 – Process of pouring liquid plaster into plaster and foam negatives to make a positive.

6. Step 3 – Negative cast markings are transferred onto positive mould before being discarded.

7. Step 4 – Rear Foot and Fore Foot corrected to Lab specifications unless mentioned on the Rx Form.

8. Step 5 – A second quality-control check is performed.

9. Step 6 – The selected shell material is then carefully heated to specific standards

10. Step 7 – Plaster corrected positive is ready for moulding of the shell in the Vacuum former

11. Step 8 – Plastic is then placed over the positive cast

12. Step 9 – High-pressure vacuum is then applied over plastic sitting on top of mould.

13. Step 10 – Formed shell is now ready to be ground into shape

14. Step 11 – Shell is shaped using various drum grinders and buffers.

15. Step 12 – A third quality-control check is performed.

16. Step 13 – Shell evaluation to corrected positive.

17. Step 14 – Desired top covers and underlay added as per Rx form.

18. Step 15 – Orthotic is then shaped to desired foot-bed, cleaned and polished

19. Step 16 – Completed orthotic goes through a 4th and final Quality control check

20. Orthotic is shipped via UPS from Lab to Clinic. Total Turnaround time – 5 to 7 business days