Custom-Molded Shoe Manufacturing Process
To ensure the perfect fit of a custom shoe, it is essential that our lab receives quality casts from practitioners. Our technicians will first review each cast for proper weight bearing and stability, as well as any close-toe wrapping techniques used by the practitioner to secure an accurate impression of their patient's foot or feet. If corrections need to be made on the cast before creating a last , meticulous measurements and tracing may be conducted using information provided in accompanying paperwork included with your order—or in rare cases we might request another casting entirely. Clear communication between all parties throughout this process is key to obtaining optimal results.
Our experienced team of technicians create a positive plaster foot with the utmost precision. Using state-of-the-art 3D scanning technology, we capture an accurate digital image before making corrections and adjustments to enhance its accuracy. We then carefully remove any excess materials from the original model prior to comparing it against customer measurements provided on the order form for verification purposes - ensuring our finished products are true reflections of your patient's feet!
The custom molded Tri-laminate insole is an essential part of creating a good pair of shoes. We always include one with each shoe - this process begins by heating up EVA blank material (or alternative materials, if the prescription calls for it) and molding them over the outer shell or "last" shape. This initial stage also involves trimming excess material to create balance before adding additional layers for depth adjustment. All of our custom insoles have been approved under PDAC code, A5513, so you can trust our superior quality.
Our team begin the process by sketching the pattern for their desired shoe on an outsole and last. After cutting and measuring paper patterns to ensure all pieces fit perfectly, these patterns are traced onto leather or other materials needed for construction - such as straps for a Velcro closure, D-rings/eyelets - then stitched into place to form a complete upper. If requested additions like padded collars or tongue padding were included in the request we'll add them now too before completing building of the upper over its last base with insoles plus mid layer added if necessary along with any possible reinforcement options like composite toe boxes & heel counters per client specifications prior to finishing off this creative masterpiece!
With the finishing touches in place, the shoes undergo their last stages of production. A welt is added for extra protection against scuffing, and special modifications like rockers, buttresses or flares are applied to customize each outsole. After detailed polishing and lacing - along with all necessary paper work – these finely crafted products become ready for shipment around the world.