CUSTOM INSOLE MOULDING PROCESS

Biomechanical Assessment for Custom Insoles

At Podiapro, we begin our custom insole moulding process with a thorough assessment of the patient’s gait and biomechanics. 

Foot analysis

The patient’s pain or complaint is clinically analyzed. The foot is palpated and its range of motion, plantar skin condition, strength of dorsiflexion and platarflexion are assessed. The condition of the patient’s plantar fascia is checked by activating the windlass mechanism. The foot-ankle alignment is observed at the posterior of the heels. A foot pressure assessment is done to further get insights into the patient’s foot pressure distribution. Such assessment helps in adding supports and reliefs at the right zones. 

Foot Pressure Scan

What is popularly called as a foot scan is actually a measurement and assessment of foot weight pressure distribution. We use the Presscam, an advanced pressure plate from Sidas, France, to measure the pressure distribution at our podiatry clinics. It is the most superior device in terms of precision and accuracy. This assessment is done in both static (standing) and dynamic (walking) conditions. It also helps in analyzing the effectivess of the custom insoles by doing a scan with the insole under the patient’s feet to see if a pressure hotspot or a diabetic ulcer area has got correctly offloaded.

Presscam Static Pressure Scan
Dynamic Foot Scan Presscam
Before and After foot pressure scans

The choice of material and the custom insole moulding process to be used for the patient is determined post this assessment. The right material and technique make the difference between custom insoles that work and those that do not. At our podiatric clinic, we make custom insoles primarily using the French custom insole moulding technique seen in the video above. 

3D Custom Insole Moulding

Custom insole moulding

At the core of our technique is the acquisition of a 3D footprint. A correctly acquired footprint enables us to make custom foot orthotics with precise shaping. This three dimensional footprint can be acquired using vacuum-silicon bags, a foam box or a 3D scanner. 

Vacuum - Silicon Bags

Vacuum powered silicon bags are used to make instant custom orthotics. The orthopedic insoles can be ready under 60 minutes using this equipment. The patient’s or athlete’s footprints are acquired by vacuum forming a negative or a cavity using the patient’s foot as the positive. The orthotic insert raw material is heated and then moulded in the negative such that it takes the shape and turns into customised inserts. This equipment helps us make and deliver same-day custom insoles with fitting in Mumbai at the Podiapro Goregaon clinic which has the workshop attached. You can get a glimpse of the steps involved in the custom insole moulding process below:

One

Custom insole process

Align foot-ankle-knee with sub-talar joint at neutral

Two

Custom insole process

Acquire instant footprint with vacuum forming technology

Three

Custom insole moulding

Place the heated shoe sole material into the negative

Four

Custom insole process

Place the feet on top of the insoles to apply pressure

Custom insole with foot

Your custom foot insoles are instantly moulded for same-day fitting

Foam Box

A foam box is used to take footprints when:

  • The patient is unable to visit our foot clinic (either they’re not mobile yet after a foot surgery) or is located in a city in which we do not have a presence.
  • The patient has a deformed or a highly rigid foot for which vacuum-silicon moulding is not suitable.

Foot positives are created from the foam box footprints using plaster of Paris and thermo-moulded insoles are fabricated on these positives.

Foam box for insoles

3D Scan

3D scanned custom insoles seem to be in trend these days, at least if you go by the marketing. However, if it’s 3D printed custom insoles they’re talking about, 3D thermo-moulded custom insoles are no match for 3D printed ones simply because we are able to use 100 various material layers including EVA insoles, PE insoles, EVA-PE insoles, memory foam insoles, PU foam insoles, Rubber, Resins in various specifications which a 3D printer cannot handle as yet. A 3D scanned insole means it is made using 3D scans of the patient’s feet. We use 3D scanners to acquire footprints in digital and store them for future use. The scanned STL file is converted into foot positives using a CNC milling machine. And we use vacuum thermo-moulding to make your custom shoe inserts on these milled positives.

Plaster Cast

Some foot deformities need us to take footprints in a plaster of paris cast, usually when we need the footprints to be very deep. 

foot plaster cast
Podiapro custom insole