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Insole Manufacture Technology

The London Orthotic Consultancy prides itself on being at the cutting edge of orthotic design and manufacture.

Because our orthotists assess, scan, aid in the manufacturing process and fit the final product to the patient, we can ensure consistency and the highest orthotic quality. It also increases the chances of finding a successful resolution to the biomechanical problem quickly.

During the initial consultation, we use a Paromed CAD/CAM scanning system to produce a three-dimensional image of the sole of the foot. Every foot is unique, so capturing the exact shape of the foot is essential for providing an accurate clinical image.

Foot Scanning Software

Scanner Software 660


We do this with the patient sat down, in a semi-weight bearing position and then correct the foot to what is the best clinically appropriate position.

We then determine the amount of wedging, or modelling, that is required under the fore and hind foot using a clinical tool called microwedge with three-dimensional computer aided design (CAD). We use this to work out how much relief is required to return the foot to a corrected position, which is customised to each patient.

Bespoke insole with foot wedging

Bespoke Insole Finished 660


Having determined what we think is the best form of wedging for the foot, the raw scan is then modelled using the same Paromed 3D modelling software where we insert wedging and add depth to different parts, such as the heel cup or the height of the arch. These all affect how the foot moves. We can also assess whether the patient would benefit from other modifications such as proprioceptive nodes which will be added at this stage.

The final modified 3D files are sent to our six-way Paromed milling machine, which manipulates a robotic arm on the end of a drill bit to carve out the insole from a blank of ethylene vinyl acetate (EVA).

Raw material insole

Bespoke Insole Start 660


The block of material will have varying degrees of density dependent on the patient’s individual needs and which type of shoe they intend to be worn in.

After the milling process, the insoles are cut from the blank and then filed down to the appropriate size and smoothed out by an orthotist.

Insoles being milled

Bespoke Insole Milling 660


Insoles being prepared

Bespoke Insole Cutting 660


Insole being smoothed & finished

Bespoke Insole Finishing 660


Our clinicians are highly qualified with a vast amount of experience in the manufacturing process of orthotics, and very often it will be the same clinician who sees the entire process through to completion.

If your orthotic insoles do not fit after the initial manufacturing process, or if they require adjustments, we can make modifications quickly and efficiently and aim to have them adjusted on the same day where possible.

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