What Are Foot Orthotics?
Foot orthotics are shoe inserts designed to support the foot and correct imbalances. It helps improve foot posture and treats certain foot and ankle problems. Podiatrists may prescribe foot orthoses for individuals with foot or leg conditions affecting their health and function. Athletes may also use foot orthoses to correct foot issues that affect their performance.
Foot orthotics are mainly of three types -
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Over-the-counter foot orthotics or off-the-shelf foot orthotics.
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Custom-made or prescription orthotics.
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“Kiosk-generated” foot orthotics.
Over-the-counter or off-the-shelf foot orthotics are the ones that are widely available and are chosen based on the condition and shoe size. “Kiosk-generated” foot orthotics are based on the foot scan. A particular orthotic is recommended based on the foot problem and foot scan.
In the case of custom-made or prescription orthotics, the podiatrists consider the patient’s health history, medical history, height, weight, activity level, etc. The best material for the patient and the level of flexibility of the orthosis are determined, and a mold impression of the foot is taken. They are used for personalized correction of biomechanical issues. They provide longer-term symptom relief and a more predictable response.
What Are the Steps Involved in Fabricating Custom-Made Orthotics?
Compared to off-shelf foot orthotics, the fabrication of custom-made orthotics involves many steps that make it more costly but, at the same time, gives more individualized results.
The different processes involved in the fabrication of custom-made orthoses by the traditional method are:
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Firstly, a biomechanical assessment is done to evaluate the function of the foot and legs and to determine joint movement and flexibility. The podiatrist conducts a detailed examination of the legs, ankle, knee, foot, and type of gait.
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The appropriate orthosis is selected depending on the foot's condition and lifestyle needs.
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The foot impression is made using a cast. These are mostly non-weight-bearing foot molds. With the patient sitting, the foot care specialist wraps the patient’s feet with plaster strips. After the plaster hardens, the strip is removed, leaving behind an accurate impression.
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It can also be made from a three-dimensional foot scan (3D custom orthotics discussed below).
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A custom-fitting orthosis is made based on the unique structure of one’s feet.
What Are 3D Custom Foot Orthotics and What Are Its Benefits?
3-D foot scanning is the newest technology in custom orthotics development. Though podiatrists still use traditional custom orthotic methods, recently 3 3-D custom orthotics are the preferred choice due to the various benefits they provide.
In this technique, a 3D digital scanner scans the individual’s feet with exceptional accuracy within seconds. The patient’s feet are scanned in a neutral non-weight-bearing position. The scanning procedure is carried out in the podiatrist’s office and the scans are sent to the laboratories for fabrication of the orthosis. The benefits of 3D scanning are:
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Better Comfort - Unlike the traditional method of taking foot impressions, in 3D scanning foot scans are made with the patient in a neutral non-weight-bearing position which is more comfortable for the patient.
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Exceptional Accuracy - 3D foot scans have 0.4 mm of accuracy. Their accuracy is exceptionally high when compared to traditional plaster impressions and other less advanced scanning methods.
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Less Environmental Waste - As the scanning procedure is purely digital, the amount of environmental waste generation is minimal compared to traditional methods. Further, there are options for more sustainable orthotics by using powder-based SLS (selective laser sintering) technologies. This allows the orthotics to be made in layers over a bed of powder, which reduces waste generation due to the use of recycled powder.
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Reduced Paperwork and More Data Security - As the procedure is completely digitalized paperwork is reduced. Data storage in the software allows podiatrists to follow up with their patients in future appointments.
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Quick Scanning - An iPad with an attached sensor scanner could be a 3D foot scanner. The scanning procedure is quick and is completed in a few seconds to minutes.
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Higher Efficiency - After taking the digital scans, they are sent to orthotic labs online. The entire procedure is faster and more efficient.
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High-Quality Orthotics - Extremely functional and high-quality foot orthotics are made using 3D scanning and the affected’s unique foot issue is addressed.
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Repeatability - As the procedure gives accurate exceptional results, these can be used to reproduce a pair identical to the original one which is not possible using conventional methods.
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Personalized Design - Individualized orthotics can be developed based on the patient’s unique foot type.
Comparison of 3D printing and the traditional process:
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A traditional foot-ankle orthotics manufacturing process may take a few days. While in 3D printing orthotics, the manufacturing process can be completed on the same day.
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In the traditional orthotics manufacturing process the measurements are taken manually, the process is more time-consuming and prone to more errors. In the 3D printing flow process the measurement is accurate and made using a 3D scanner.
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The number of steps involved in 3D printing flow is less when compared to traditional methods.
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It is difficult to make customization without compromising quality in traditional methods. In 3D printing flow customization is possible by accessing the stored data without compromising the quality.
What Are the Different Steps Involved in 3D Printed Orthotics Workflow?
The 3D-printed orthotics workflow consists of the following steps:
1. Scanning:
The initial step is scanning the affected limb. The pathological limb is positioned to take the scan. The landmarks are added by the technician and the process is less time-consuming when compared to conventional mold technique.
2. Modeling and Modification:
There is no need for mold making and drying process, the technician can directly move into modeling and modification of the scan. Positioning does not take more than a few minutes. Modeling software is used.
3. 3D printing:
The printing process is completed in a few hours. A model of the prosthesis is made.
4. Post Processing:
In this step, the support parts are removed and the insole surface is polished.
5. Installation and Use:
The equipped insole is placed inside the shoes and the position is adjusted.
Conclusion
3D printing provides a more simplified process for orthopedic technicians, is more convenient for the patient, and has exceptional accuracy and higher efficiency among other benefits. The chances of error and inaccuracies with the technique are very rare. Add to add more it also reduces the time spent on manual and repetitive tasks.
