Foot Mould and Orthotic Manufacture Guide
Rather than go by the shoe size, we are better off holding the blank directly to the foot and fitting just proximal to the met head. Two people might wear the same size of shoe but have different size orthotics. We are interested in the arch length not the shoe size.
After deciding which blank to use, hold it directly to the foot. Do not fit the blank while the patient is standing on the device, you need to see where the orthotic lines up under the foot.
Make sure the rear of the orthotic is sitting a little behind the heel of the foot - this simulates where it might hit the back of the shoe.
If neccessary, dosalflex the great toe so you can see the met head clearly. Fit proximal to the met head. If you want to fit long, you can go as close as 3mm or 1/8 inch proximal to the bisection of the met head.
If you fit long, be aware that you might need to bend the edge down
so the patient does not feel the edge of the device when they walk.
so the patient does not feel the edge of the device when they walk.
A heat gun is not a hair dryer! You need a paint stripper,which you can purchase at any DIY shop. Place the blank on a surface that will not get burned from high heat.
HOLD THE GUN 1 CM OR JUST OVER 1/2 AN INCH AWAY FROM THE BLANK.
The average time is about 1.5 minutes to soften. Bigger sizes may take longer. Do not stop moving the heat gun - you will melt the orthotic!
The average time is about 1.5 minutes to soften. Bigger sizes may take longer. Do not stop moving the heat gun -
Toaster Oven
Pre-heat toaster oven to 300 degrees for 5 minutes until the oven is red hot.
When the oven first comes on it is too hot until it preheats. After the oven is preheated place both orthotics inside.
Pre-
When the oven first comes on it is too hot until it preheats. After the oven is preheated place both orthotics inside.
Size
Approximate time
Size
Approximate time
A (3-4)
1 min
E (8-9)
2 min 45 sec
B (5-6)
1 Min 30secs
F (9-10)
3 min
C (6-7)
1 min 45 sec
G (10-11)
3 min 15 sec
D (7-8)
2 min 15 sec
H (12-14)
3 min 30 sec
When they are ready, pull both orthotics put of the oven and mold. If you do one at a time, you may need to reheat the second for 15-30 seconds.
When the orthotic becomes soft you may push the arch all the way down to check it for softness. If it is still stiff in the middle, place back in the oven for 10-15 seconds.
When the orthotic becomes soft you may push the arch all the way down to check it for softness. If it is still stiff in the middle, place back in the oven for 10-
There is an argument on neutral position vs. the calcanial resting position. We take no sides, but will show both methods.
You can mould the blank while sitting, standing in the shoe, on a pillow or whatever you are most comfortable with.
You can mould the blank while sitting, standing in the shoe, on a pillow or whatever you are most comfortable with.
Do not mould directly to the foot, even if the patient is wearing a sock. You can double a thick towel or washcloth or use the protective Hot Top covering that we provide.
Make sure the rear of the orthotic is not too far forward on the foot and that the medial (or inside of the foot) covers the arch entirely.
First is the back of the arch on the medial side. The best way to avoid this is to make certain the arch is entirely under the foot.
If there is a complaint about the arch being too high, take a heat gun or paint stripper and heat the back of the arch.
To avoid any problems, make certain the back of the foot is aligned all the way on the medial side.
If there is a complaint about the arch being too high, take a heat gun or paint stripper and heat the back of the arch.
To avoid any problems, make certain the back of the foot is aligned all the way on the medial side.
The other possible area of concern is the distal edge (or front) of the orthotic. Depending on the shoe the patient is wearing, this edge may not be sitting flush in the shoe.
There can be a significant gap that needs to be corrected.
There can be a significant gap that needs to be corrected.
After the patient has moulded the orthotic on a pillow, place it in the shoe while it is still warm. Push on the heel area with your thumb and feel the front edge with your fingers to determine if it makes a smooth transition into the shoe.
If there is a gap, place the orthotic on an edge and downward flex to
If there is a gap, place the orthotic on an edge and downward flex to
adjust it to the shoe. You are not trying to raise the arch as much as you are adjusting the front edge. Test it in the shoe.
You can also mould specific parts of the orthotic with a heat gun for adjustment as needed. Cooling them in water will not harm the material.
You may see waves in the orthotic plate. This is the bony prominences of the foot that have been captured in the orthotic and is an accurate mould that should be comfortable on the foot.
You can also mould specific parts of the orthotic with a heat gun for adjustment as needed. Cooling them in water will not harm the material.
You may see waves in the orthotic plate. This is the bony prominences of the foot that have been captured in the orthotic and is an accurate mould that should be comfortable on the foot.
The patient can mold directly in the shoe by using the shoes insole as a heat protector.
Place the hot orthotic underneath the insole and have the patient stand in place.
Place the hot orthotic underneath the insole and have the patient stand in place.
You can mould directly inside a high heel shoe if you cover the orthotic to protect the foot from the heat.
You can also mould on a pillow, then modify the blank while it is still warm to fit a high heel shoe.
You can also mould on a pillow, then modify the blank while it is still warm to fit a high heel shoe.
Slightly bend the forefoot to accommodate the angle of the high heel. Make certain the distal edge is flush with the shoe so they don't feel the edge of the orthotic.
Using the top cover materials provided by TFOL, first peel back the adhesive paper on the base of the top section and And stick this onto the top of the orthotic. Now peel back the adhesive paper on the base section .
Stick this on the distal aspect of the shell and plantar aspect of the top cover.
Cut the plantar addition to size with the top cover.
Cut the plantar addition to size with the top cover.
And the top cover is finished. Plantar pressure distribution pads or further cushioning can be added as required.
Add masking tape to the heel cup section the glue is to be applied to.
Then remove the tape and apply glue to the 6mm EVA wedge to be used
Heat the EVA in a toaster oven or with a heat gun until it is nearly too hot to hold but flexible (you may need to use Kevlar gloves)
Stick the EVA to the shell and then using scissors cut off the spare EVA
Use a grinder to reduce the EVA to the required angle to finish the post.