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PROCESSING OF THE FOOT ORTHOTIC BLANKS

To meet the needs of each patient and in order to successfully treat the diverse pathological findings in your patients’ feet, it is essential to manufacture foot orthotics individually. However, the processing of bespoke foot orthotics from the scratch is time- and cost consuming and requires expertise in the processing and regarding to the materials used.

So how can you optimize the manufacturing process of custom foot orthotics, without compromising the quality and individuality of your orthotics?

The solution is simple: With help of Perpedes’ thermal moldable and thereby fully customizable foot orthotic blanks. The foot orthotic blanks come in various styles and shapes and are developed to treat most common foot ailments.

All Perpedes' foot orthotic blanks have an incorporated glass or carbon fiber shell. Due to the thermoplastic properties of the fiberglass shells, the blanks can be uniquely adapted to the patient’s feet and its specific needs.

Click here for an overview of the Perpdes' foot orthotic blanks portfolio.

HOW TO PROCESS THE PERPEDES' FOOT ORTHOTIC BLANKS

In addition to the following explanations you may want to watch the full video on how to process the Perpedes' foot orthotic blanks here.

1. PREPARATIONS

The positive (plaster cast, insole last) should have an even forefoot area to avoid wrinkles in the foot orthoses during the molding process. 

Choose a foot orthotic blank type that fits the indication, the foot length and that suits to the footwear of your patient. Simply use our “Product Selection Guide” as it is a perfect tool to support your treatment decisions. For choosing the correct size of the foot orthotic blank, you can check out our „Size conversion table“. However, all measurements are recommended to make on the foot imprint, generated in full weight bearing.

2. HEATING

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Heating is suggested either in a convection oven or between warming plates. Direct contact between the orthotic‘s base layer and the oven‘s grate should be avoided (Teflon film recommended).

The recommended heating temperature is at about 140° C (284° F). Heating time is approx. 4 - 8 minutes (depending on blank materials, thickness, heat source). The incorporated orthotic shell must be thoroughly warmed and flexible prior to vacuum shaping.

Thermal alterations on the blanks with already glued top covers should be done only partially from the bottom side with a heat gun.

 Thermal molding at too low temperatures leads to damage of the material, while too high temperatures (>160° C / 320° F) may cause the composite fiber shell getting brittle.

3. THERMAL MOLDING

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A heated composite fiber can best be molded under vacuum onto a positive. Further processing is recommend only after complete cooling under vacuum. To shorten processing time, a cold wet towel proves useful onto the vacuumed orthotic blank.

When warming up, the adhesive in pre-fab blanks is being re-activated, so the layers of the various components might slightly delaminate. This effect is reversible when the foot orthotics have cooled down while being pressed together.

4. ASSEMBLING THE TOP COVER

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Now optionally assemble a met pad and a heel post (Perpedes Balancer). Mandatory is the compeletion of the orthotics with a top cover.

5. FURTHER PROCESSING

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 Finally, the foot orthotics are being trimmed and finished by grinding.

 6. FINISHED AND READY TO BE DISPENSED TO THE PATIENT!

Einlage

With help of Perpedes’ foot orthotic blanks you get fully custom foot orthotics, quick and easy made, without compromising quality, treatment schemes or requirements.

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