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How Are Custom Orthotics Made? A Step-by-Step Guide

How Are Custom Orthotics Made? A Step-by-Step Guide

Manhattan Podiatry Associates | Two Convenient Locations in Midtown & Downtown NYC

If you suffer from foot pain, custom orthotics can provide the support and alignment your feet need. Unlike generic, over-the-counter insoles, custom orthotics are tailored to your unique foot structure and biomechanics, offering superior comfort and relief.

At Manhattan Podiatry Associates, our board-certified podiatrists specialize in both functional and accommodative orthotics, helping patients at either the Midtown and Downtown New York City locations. 

Here’s a closer look at how custom orthotics are made.

Step 1: Comprehensive foot evaluation

Before your custom orthotics are made, your first step is to schedule an evaluation at one of our NYC offices with our Board Certified doctors.

Your evaluation may include:

A review of your symptoms

Please share with us ALL of your symptoms. Think about if OR when any pain starts or stays, what makes it worse (or better), and when the problem started. 

For example, many people with plantar fasciitis report that their pain is worse first thing in the morning and after periods of inactivity. 

Gait analysis 

Orthotics can correct abnormal foot motion, so we will observes how you walk to identify any imbalances. 

There are many methods for helping you with a gait analysis, from pressure platforms to computer software to cameras, AND they’re all noninvasive so it is an easy in office evaluation.  We can also calculate your stride length.

Foot measurements

Your Manhattan Podiatry Associates podiatrist will also measure your arch height, assess your foot shape, and look for pressure points.

Medical history review 

It is also important to look at the big picture. Many people do not think of your medical history (beyond your foot health) as fully important as it really is when planning for orthotics; the reality is that it’s VERY important. That’s why we also discuss your full medical history, which includes foot conditions like plantar fasciitis, flat feet, or bunions, and medical conditions like diabetes.

Orthotics are especially beneficial for individuals with diabetes because they provide support, reduce pressure points, and help prevent foot ulcers and injuries

Ulcers can lead to serious complications like gangrene and amputation, but orthotics alleviate pressure, which, in turn, helps prevent ulcers from forming in the first place.

Step 2: Foot impressions or digital scans

Once we've assessed your foot health, it’s time to create a precise mold of your feet. This can be done using foam casting, plaster casting, or 3D digital scanning. We’ll walk you through each step of the process when you arrive.

Step 3: Orthotic design and material selection

This step sets your custom orthotics apart from the one-size-fits-all, over-the-counter shoe inserts. Your orthotics are designed based on your foot structure and specific needs. Different materials are used depending on the level of support you require. 

Rigid orthotics are made from carbon fiber or plastic. These functional orthotics are less flexible and ideal for those with heel pain, tendonitis, or arch support issues. Semi-rigid orthotics combine firm support with some flexibility for athletic use.

Soft orthotics (accommodative orthotics) use cushioning materials designed for conditions like diabetic foot ulcers, calluses, foot deformities, or arthritis. 

Your orthotics are made to your specific and unique foot anatomy so you can get pressure relief or added support where you need it most.

Step 4: Custom fabrication

This is when your orthotics are actually created. We send your orthotic designs to a specialized lab where skilled technicians create your inserts. 

Using the mold or digital scan our team sends them, they cut, shape, and assemble your orthotics to match the precise specifications you need.

Step 5: Fitting and adjustments

Once your orthotics are ready, you return to our office for a fitting. During this visit, we test your orthotics to make sure they fit inside your shoes properly. We have you walk around to test comfort and support. If needed, minor adjustments are made for the perfect fit.

Step 6: Follow-up care

Your feet may take time to adjust to the new support. We’ll guide you on how to:

Over time, your orthotics may need to be replaced. Softer orthotics can wear out faster than more rigid versions. Your activity levels might also impact the life of your orthotics. If your symptoms return or you suspect your orthotics are worn out, give us a call. 

Experience custom orthotics for yourself

Get Custom Orthotics at Manhattan Podiatry Associates

If you're struggling with foot pain, misalignment, or pressure-related conditions, custom orthotics can provide the support and relief you need. At Manhattan Podiatry Associates, our expert podiatrists offer personalized orthotic solutions tailored to your unique foot structure and lifestyle.

With two convenient locations in Midtown and Downtown NYC, we make it easy to get the care you deserve.  Schedule an appointment with our team today.

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