How Is an Orthosis Made?

While orthoses can be made by several different processes, most podiatrists and physicians prefer to make a plaster cast or plastic foam of the patient's foot. This is called a negative impression. The cast is sent to a laboratory with a prescription for recommended modifications. At the lab, a positive cast is made by pouring plaster into the negative cast. When this dries, it forms a perfect reproduction of the bottom of the foot. Using the doctor's recommendations for corrections, the pedorthist custom-mold an orthosis that incorporates the necessary adjustments. This will provide the patient with the support, stability, cushioning and alignment necessary to keep his or her, ankles and lower body comfortable, healthy and pain-free.

Then they cut, carve, or grind the material, using hand or power tools. After they cook the material in the convection oven, they put the material on the positive cast to shape the material according to modified cast.

Finally, technicians use grinding or buffing wheels to shape and smooth shell. They may also cover or pad the shell with rubber, leather, felt, plastic, or other coverings. For example, they may pad metatarsals at the points of contact with foot. They may cover arch supports with felt to make them more comfortable. Pedorthists use a wide variety of materials.

Pedorthists test devices for proper alignment and movement. They may test the devices both on and off the patient. They also fit devices onto patients and make adjustments if they are needed. Most pedorthists repair and maintain the devices they make. In addition, some pedorthists teach patients how to use these devices.

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