How Are Orthotics Made?

Premier’s Orthotic Process – The Building of a Great Orthotic

Orthotic Process Premier Orthotic Labs Burlington

In order for POL to supply you with a truly custom product, we first receive a foam or plaster cast impression of your foot corrected in sub-talar neutral.

Once your cast impression is received, we start our Quality Control process.

Your order and the selected materials and choice of correction as well as shoe selections is confirmed by our dedicated and highly competent customer service team.

Measurements of the cast are taken and marks are placed on the negative cast impression to indicate bony prominences such as 1st met head and 5th met head, navicular and sulcus line. The Calcaneous is marked for mid line vertical and then a plaster positive mould is made from the negative cast.

Burlington Orthotics Premier Lab
Process of pouring liquid plaster into plaster and foam negatives to make a plaster positive.

Once the plaster is cured, the negative mould is broken away and discarded. The markings on the negative cast impression transfer onto the new plaster positive.

The rear foot and fore foot are corrected to lab evaluation or otherwise instructed via the prescription form (Rx form).

Premier Orthotics Lab Process
Once the plaster positive is corrected another Quality check is performed including a complete evaluation of the cast dressing, rear foot alignment, forefoot alignment in plane with the rearfoot and amount of tissue expansion necessary.

The Rx form will indicate which types of materials to use in the fabrication process and any other special instructions.

The shell material selected will be heated and then vacuum moulded following specific standards used at POL based on the material, its thickness and overall desired effect of support required by the patient.

Premier Orthotics Lab Process
Plastic being heated according to specific standards.
Premier Orthotics Lab Process
Plaster corrected positive is ready for moulding of the shell in the vacuum former.
Premier Orthotics Lab Process
Plastic is placed over the positive.
Premier Orthotics Lab Process
Vacuum is applied and the table top platen cover bladder is drawn over the plastic over the mould to form the desired shell shape and design.
Premier Orthotics Lab Process
The formed shell ready to be ground into shape to the foot and desired footwear.
Premier Orthotics Lab Process
The shell is shaped using various grinders and buffers

After the shells are ground, a third Quality check is performed. The choice of material, the length of the shell, width of the shell, the intrinsic and extrinsic posting of the shell, any shell modifications and fitment into desired footwear are evaluated.

Premier Orthotics Lab Burlington Ontario
Shell evaluation to corrected positive.

Once passed, the order is then processed to select the desired soft materials required to finish the fabrication of the product.

The order is then in production for completion.

Premier Orthotics Lab Process
Desired soft materials are in the process of being applied to the shell.

Once the orthotic is finally put together, it is then shaped again to the desired foot bed , cleaned and polished.

The order then goes through its final 4th Quality Control check.

Premier Orthotics shipping

The orthotic is evaluated on its cosmesis, functionality, performance, prescription order and all paper work, including labels.

The order proceeds to the shipping department to be packaged on its way to the prescribing practitioner with any other product or materials requested.

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Service

We back our product and offer excellent support for fitting and adjusting.

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Quality

Custom made orthotics that last! Your customers will be impressed.

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Care

Our customers are the backbone of our business. We make sure you are cared for.