Metatarsal Pads
With our expert Pedorthists and cutting edge software, we can make you the most accomodating orthotic. Our software allows us to see a 3D visualization of the orthotic before it is manufactured, giving us the ability to build it exactly to your individual specifications.
Wedges can be added under the heel of any arch support. It is very common to wedge the heel of an Orthotic to gain more control. Improving bad alignments can help ankles, knees, and lower back. We recommend you do not go above 6mm in wedges unless you have had experience using them or prescribe by your doctor. Wedges will change your alignment and can cause discomforts in the body for up to 30 days. These discomforts will fade as the body adjusts to its new alignment.
Heel lifts are added to one of the Orthotics to lift the heel. They are most commonly used when one leg is shorter than the other. Make sure you select the lift on the shorter leg. There are some cases were both heels are lifted such as Achilles pain and Plantar Fasciitis. When you raise both heels there is less strain on the calf muscle, attaching tendons, and the plantar fascia tissue. A wedge can also be added with a heel lift.
EVA Accomodating Foam
Thickness
Each orthotic is milled out with a standard 3mm base. Base means the thickness of material on the toe area before a top cover is added. An orthotic with a 3mm base and a 3mm top cover will have 6mm total thickness. Try to match the total thickness ordered with the footwear it will be worn in. For example, most athletic shoes have a removable insole that measures close to 6mm thick. Casual shoes commonly only have a 3mm removable insole, while dressier shoe may only have 2mm or no removable insole. Customer satisfaction is hard to maintain when ordering a 6mm thick orthotic to fit into footwear that only has room for 3mm. A specific base layer can be requested in the notes to over ride the 3mm default value. Ordering a soft density with a thicker base such a 5mm will increase comfort and durability. Decreasing the base thickness in a firm density to 1mm will produce a much thinner orthotic. It is not recommended to order a soft Eva with less then 3mm or a firm Eva thicker then 3mm. Here are some examples of our program and its custom options.
Soft Eva-45 Durometer
Medium Eva-55 Durometer
Hard Eva-65 Durometer
Plastic Thickness 1/8" Plastic: used when a flex is desired. Select this thickness for dressier shoes or when a rigid arch is not desired. You will gain increased support in shoes but not overwhelming pain from an aggressive arch support. Works great for runners who want to increase support but still want the arch to flex. Recommended for body weight up to 140 lbs. 3/16" Plastic: used when arch support is the main focus. For most people this thickness will prevent the arch from dropping. It is the normal thickness for orthopedic devices especially for treating Plantar Fasciitis. This thickness maintains solid support for up to 180 lbs or a men’s shoe size 12. After that some mild flex will occur but still offer great support. 1/4" Plastic: used for maximum support. Has no flex in the arch. Recommended for body weight of more than 220 lbs or shoe sizes larger than men’s 13.
Before we begin manufacturing, we need an accurate foot shape to process. Many internet orders and low volume facilities like the easy and low cost solution of Bio-Foam casting kits. Arch Fitters will supply all internet orders with a free kit. Larger volume facilities love the speed and accuracy of our digital scanner. We are proud of our reputation of being one of the fastest central manufacture labs in the USA.
Designing the shape and function of each orthotic takes years of experience using our state of the art software, Solid Works. Each orthotic is programmed by one of our senior orthotic designers using this extremely accurate modeling program, Solid Works to achieve accuracy. Wedges, heel lifts, Metatarsal supports, and other options are programmed with precision. Each orthotic has 900 control points for infinite manipulation.
In simple terms we start with a full sheet of Ethylene Vinyl Acetate (EVA) roughly 1 ½ inches thick. The computer carves out the EVA to the exact 3D shape derived by Solid Works. The amazing part is, our CnC machines must execute 1200 movements to cut out each orthotic. With this many movements each orthotic comes out smooth and accurate each time.
In the final stage a top cover is added and the orthotic is trimmed to the selected shoe size. There are many top covers to select from each having a unique purpose. Detail descriptions can be viewed by clicking here. After the orthotic has been completed and inspected for quality assurance, it is then mailed out. This entire process takes about 24 hours. Once we get your cast via mail or electronic upload, Arch Fitters will manufacture and ship within 24 hours.
Before we begin manufacturing, we need an accurate foot shape to process. Many internet orders and low volume facilities like the easy and low cost solution of Bio-Foam casting kits. Arch Fitters will supply all internet orders with a free kit. Larger volume facilities love the speed and accuracy of our digital scanner. We are proud of our reputation for being one of the fastest central manufacture labs in the USA.
Designing the shape and function of each orthotic takes years of experience using our state of the art software, Solid Works. Each orthotic is programmed by one of our senior orthotic designers using this extremely accurate modeling program. Solid Works to achieve accuracy. Wedges, heel lifts, Metatarsal support, and other options are programmed with precision. Each orthotic has 900 control points for infinite manipulation.
After the orthotic is designed, a wooden mold is cut out. A mold is a hard representation of a person’s foot with corrections. The corrections are necessary to medically align the foot and help heal, correct, or comfort each unique foot concern. Once the mold is finished it is prepped and put into a vacuum bladder system. This system is commonly known as vacuum forming. A layer of plastic, graphite, or EVA will form over these molds. In most cases the material is heated up to a certain temperature that allows it to be flexible. It is at this point the rubber bladder is closed and all air is sucked out of the unit. This causes the top rubber bladder to form over the molds forcing the material to take thier new shape. Once the heated material cools long enough the new shape becomes permanent. Thicker plastic and graphite takes longer to form.
Once you remove the formed plastic or material from the mold, there is a lot of excess plastic. This material needs to be removed from the orthotic or it will not fit into shoes. After the shape and profile is achieved, each orthotic is hand buffed to remove any jagged edges or rough spots. Reshaping the orthotics takes great skill and artistic abilities. Taking something that is ugly and making it beautiful is something very few people can do. Arch Fitters is proud to have production staff that takes pride in their work. The products are of such a high quality that some people can’t believe our products are hand made because they look too good.
In the final stage a top cover is added and the entire orthotic is trimmed to the selected shoe size. There are many top covers to select from, each having a unique purpose. Detailed descriptions can be viewed by clicking here. After the orthotic has been completed and inspected for quality assurance, it is then mailed out. This entire process takes about 24 hours. Once we get your cast via mail or electronic upload, Arch Fitters will manufacture and ship within 24 hours.