How we design and manufacture our bespoke insoles

Since our orthotists handle every step of the process, from assessment and scanning to manufacturing and fitting, we ensure a consistently high standard of quality. This hands-on approach also helps us quickly find the best solution for each patient’s biomechanical needs.

How we manufacture our bespoke insoles

We use highly accurate technology and software to ensure the highest quality insole manufacturing. The process involves:

1. Biomechanical assessment: a thorough evaluation of foot structure, gait, and alignment.
2. 3D foot scanning: using the Paromed CAD/CAM scanning system, we create a precise three-dimensional image of the foot in a semi-weight-bearing position.
3. Correction and customisation: we adjust the foot to the most appropriate position and use a micro-wedge tool plus CAD software to determine the exact modifications needed.
4. Manufacturing: the insoles are crafted with precision, ensuring they provide the necessary support and corrections for the patient’s foot structure.
5. Fitting and adjustment: patients receive a final fitting, and any necessary refinements are made to ensure optimal comfort and effectiveness.

Biomechanical foot assessment

During your initial consultation, we use a Paromed CAD/CAM scanning system to create a precise three-dimensional image of the sole of your foot. Since every foot is unique, capturing its exact shape is essential for an accurate clinical assessment.

This scan is taken while you are seated in a semi-weight-bearing position, allowing us to correct your foot to the most clinically appropriate alignment.

Next, we determine the amount of wedging or modelling required under the forefoot and hindfoot using a micro wedge and three-dimensional computer-aided design (CAD) technology. This step ensures that we can provide the right amount of support and relief to return your foot to a corrected and optimised position.

Making your bespoke insole

Once the optimal wedging and corrections have been determined, we use Paromed 3D modelling software to refine the scan. At this stage, we adjust depth and shape in key areas, such as the heel cup and arch height, to fine-tune how the insole influences foot movement.

The final 3D-modified files are then sent to our six-way Paromed milling machine, which uses a robotic arm with a drill bit to carve the insole from a block of ethylene-vinyl acetate (EVA).

The material density of the EVA block is selected based on your individual needs and the type of footwear you plan to use with the insoles.

After the milling process, the insoles are precisely cut from the blank, then filed and smoothed to the appropriate size by your orthotist, ensuring an optimal fit for both comfort and function.

Fitting

Your clinician will then fit your bespoke insoles and ensure they are comfortable.

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.

Express insole service in Kingston

We offer an express orthotic insole service at our Kingston clinic for those who need insoles manufactured quickly.

This service allows for the assessment, manufacture, and fitting of bespoke insoles within two hours, including late evening appointments on Thursdays for added convenience.