Foot Impression & Frame Fabrication Methods

Common methods for capturing a patient’s foot contour and 5 different lab methods for orthotic frame fabrication.

Orthoses Materials

Anti-pronation

Anti-supination

Forefoot Extensions

Offloading Pads & Cushions

Frame Modifications

Foot Impression Methods

There are 7 common methods for capturing a patient’s foot contour: Plaster Slipper Cast, Foam Impression, STS Slipper Sock, 3D Scan, Pedobarography, Positive Model and Redimold.

Plaster Slipper Cast

Foam Impression

STS Slipper Sock

3D Foot Scanner

Pedobarography

Existing Positive Model

Redimold

There are 5 different lab methods for orthotic frame fabrication: Plaster Positive Model Vacuum Formed, CAD CAM Positive Model Vacuum Formed, 3D Printed Frame, Direct Mill Frame and Redimold Vacuum Formed. Tolerances in foot impression methods and fabrication methods produce variable outcomes for how similarly the orthotic frame matches the patient’s foot.

Plaster Positive M.

CAD CAM Positive M.

3D Printed Frame

Direct Mill Frame

Redimold Positive M.

The chart below shows outcomes of shape-contour variation between foot, foot-model and orthotic frame when different methods are combined. Congruent accuracy is a measure of how closely the orthotic frame matches the patient’s foot in the exact position the patient’s foot impression was captured.

Foot Impression and Frame Fabrication Method Outcome Variation Chart

Indicate in special instructions if specific Fabrication Method is desired. Account standards can be set up by emailing hello@kevinrootmedical.com.

* Because the redimold method has no physical or digital foot impression, the congruent accuracy from patient foot to cast is unavailable. However, the congruent accuracy from positive model to vacuum formed frame has a low degree of variation.

Standard Orthotic Lab Methods for Frame Fabrication and Foot Model Data Storage

* Requests to change standard frame fabrication methods and foot model data are welcome. To change a clinician’s fabrication and foot model data storage methods contact hello@kevinrootmedical.com

If plaster slipper cast, impression foam cast or STS slipper socks foot impression method is used, the foot model data storage can be selected per order.

Store plaster positive mold for 3 months (lab standard): If requested, the storage of plaster positive molds will be held for 3 months if modifications or additional pairs are needed.

Digitize my impression: KevinRoot Medical will use a 3D method to create a digital positive model which is stored indefinitely and can be recalled for fabricating consistent orthotics.

Note on Digitizing Positive Models: If a positive plaster model is digitized, KevinRoot Medical cannot guarantee replicating the exact and intimate contours that were vacuum formed over the positive plaster model previously.
Note on Digitizing Deep Heel Cups and Flanges: For very deep heel cups, medial and lateral flanges, such as UCBL devices, digitizing impressions or using digital fabrication methods are not recommended.

Return positive model: Positive models can also be returned with the orthotic devices and patients can be responsible for storage if future pairs or modifications are needed.

There are 7 common methods for capturing a patient’s foot contour: Plaster Slipper Cast, Foam Impression, STS Slipper Sock, 3D Scan, Pedobarography, Positive Model and Redimold.

Plaster Slipper Cast

Foam Impression

STS Slipper Sock

3D Foot Scanner

Pedobarography

Existing Positive Model

Redimold

There are 5 different lab methods for orthotic frame fabrication: Plaster Positive Model Vacuum Formed, CAD CAM Positive Model Vacuum Formed, 3D Printed Frame, Direct Mill Frame and Redimold Vacuum Formed. Tolerances in foot impression methods and fabrication methods produce variable outcomes for how similarly the orthotic frame matches the patient’s foot.

Plaster Positive M.

CAD CAM Positive M.

3D Printed Frame

Direct Mill Frame

Redimold Positive M.

The chart below shows outcomes of shape-contour variation between foot, foot-model and orthotic frame when different methods are combined. Congruent accuracy is a measure of how closely the orthotic frame matches the patient’s foot in the exact position the patient’s foot impression was captured.

Foot Impression and Frame Fabrication Method Outcome Variation Chart

Indicate in special instructions if specific Fabrication Method is desired. Account standards can be set up by emailing hello@kevinrootmedical.com.

* Because the redimold method has no physical or digital foot impression, the congruent accuracy from patient foot to cast is unavailable. However, the congruent accuracy from positive model to vacuum formed frame has a low degree of variation.

Standard Orthotic Lab Methods for Frame Fabrication and Foot Model Data Storage

* Requests to change standard frame fabrication methods and foot model data are welcome. To change a clinician’s fabrication and foot model data storage methods contact hello@kevinrootmedical.com

If plaster slipper cast, impression foam cast or STS slipper socks foot impression method is used, the foot model data storage can be selected per order.

Store plaster positive mold for 3 months (lab standard): If requested, the storage of plaster positive molds will be held for 3 months if modifications or additional pairs are needed.

Digitize my impression: KevinRoot Medical will use a 3D method to create a digital positive model which is stored indefinitely and can be recalled for fabricating consistent orthotics.

Note on Digitizing Positive Models: If a positive plaster model is digitized, KevinRoot Medical cannot guarantee replicating the exact and intimate contours that were vacuum formed over the positive plaster model previously.
Note on Digitizing Deep Heel Cups and Flanges: For very deep heel cups, medial and lateral flanges, such as UCBL devices, digitizing impressions or using digital fabrication methods are not recommended.

Return positive model: Positive models can also be returned with the orthotic devices and patients can be responsible for storage if future pairs or modifications are needed.

There are 7 common methods for capturing a patient’s foot contour: Plaster Slipper Cast, Foam Impression, STS Slipper Sock, 3D Scan, Pedobarography, Positive Model and Redimold.

Plaster Slipper Cast

Foam Impression

STS Slipper Sock

3D Foot Scanner

Pedobarography

Existing Positive Model

Redimold

There are 5 different lab methods for orthotic frame fabrication: Plaster Positive Model Vacuum Formed, CAD CAM Positive Model Vacuum Formed, 3D Printed Frame, Direct Mill Frame and Redimold Vacuum Formed. Tolerances in foot impression methods and fabrication methods produce variable outcomes for how similarly the orthotic frame matches the patient’s foot.

Plaster Positive M.

CAD CAM Positive M.

3D Printed Frame

Direct Mill Frame

Redimold Positive M.

The chart below shows outcomes of shape-contour variation between foot, foot-model and orthotic frame when different methods are combined. Congruent accuracy is a measure of how closely the orthotic frame matches the patient’s foot in the exact position the patient’s foot impression was captured.

Foot Impression and Frame Fabrication Method Outcome Variation Chart

Indicate in special instructions if specific Fabrication Method is desired. Account standards can be set up by emailing hello@kevinrootmedical.com.

* Because the redimold method has no physical or digital foot impression, the congruent accuracy from patient foot to cast is unavailable. However, the congruent accuracy from positive model to vacuum formed frame has a low degree of variation.

Standard Orthotic Lab Methods for Frame Fabrication and Foot Model Data Storage

* Requests to change standard frame fabrication methods and foot model data are welcome. To change a clinician’s fabrication and foot model data storage methods contact hello@kevinrootmedical.com

If plaster slipper cast, impression foam cast or STS slipper socks foot impression method is used, the foot model data storage can be selected per order.

Store plaster positive mold for 3 months (lab standard): If requested, the storage of plaster positive molds will be held for 3 months if modifications or additional pairs are needed.

Digitize my impression: KevinRoot Medical will use a 3D method to create a digital positive model which is stored indefinitely and can be recalled for fabricating consistent orthotics.

Note on Digitizing Positive Models: If a positive plaster model is digitized, KevinRoot Medical cannot guarantee replicating the exact and intimate contours that were vacuum formed over the positive plaster model previously.
Note on Digitizing Deep Heel Cups and Flanges: For very deep heel cups, medial and lateral flanges, such as UCBL devices, digitizing impressions or using digital fabrication methods are not recommended.

Return positive model: Positive models can also be returned with the orthotic devices and patients can be responsible for storage if future pairs or modifications are needed.