Equipment for manufacturing orthopedic insoles

Today we will talk about 3D scanners for orthotics from ScanPod3D.

Manufacture of custom orthopedic insoles

Production of individual insoles in the SportKlinik's 'foot and running laboratory'.

The production of individual insoles is a separate area of orthopedics aimed at correcting various pathological conditions of the foot, but also of the entire skeletal system - ankle, knee, hip and spine. Only custom-made orthopedic insoles accurately replicate the structure of the foot, keep all parts of the foot in the correct position, correct and prevent the development of various foot deformities, relieve stress on the entire musculoskeletal system, reduce injuries and prevent signs of foot fatigue.

A revolutionary breakthrough in this area has been achieved by SIDAS, which has developed a new technology for diagnosing foot problems and producing tailor-made orthopedic insoles based on an analysis of the biomechanical properties of the foot when walking or running. SIDAS was launched in France in 1975 and has since become a global leader in this field. SIDAS products are used by athletes of various categories and are particularly popular among skiers, hockey players and other professional and amateur athletes. Today, no ski or snowboard shop can be imagined without SIDAS products. And that's not just a fad - SIDAS technology really makes every shoe comfortable.

The most important advantages.

There are many reasons to choose SIDAS:

USOL.

It is the most compact scanner of all and weighs only 4.7 kg. It's fast, portable and affordable. It scans one stack at a time, but there is also a USOL-DUO model that can scan two stacks at the same time.

On the front there is a vertical stripe with a laser that helps align the foot and ankle. On the back there is a small folding bracket with a camera for examining the heel.

The scanner can also be used vertically thanks to a special tripod.

The USOL's scanning speed is even faster than its competitors at 2.9 seconds (1.9 seconds for high-speed scanning).

The scanning height is 80 mm, which is significantly lower than other models. This scanner is therefore more suitable for creating individual orthopedic shoe insoles.

UPOD-S

The UPOD-S is a compact device weighing just 10kg that can scan one foot at a time.

The maximum load capacity of the scanner platform is 130 kg, which is 50 kg less than the USOL and UPOD-HD.

Scanning area size: 330mm×130mm×115mm. Thanks to the height of 115 mm, the foot can be scanned from the instep to the ankle. But the scanning speed is also slightly faster than the USOL – 3.2 seconds per page.

A white plastic cap with a recess and a comfortable silicone foot ring provide the necessary shading during operation. No additional shading or covering is required.

There is a scanning sensor on the top of the scanner that flashes blue during operation.

On the back are the connectors for the power supply, computer, power button, camera indicators and monitor stand mounting options.

From the inside the scanner looks like this:

There are LED strips on all sides that illuminate the object being scanned, and there are also 3 cameras inside: right, left and center.

The large scanning height allows the limits of the scanner to be expanded and the UPOD-S can be used for both insoles and shoes.

How it's done now

The first solution presented is the Ecco Quant-U. This is a complex for scanning feet and printing insoles. An Ecco employee explained to us how the process itself works.

The device can scan the fullness of the foot like a traditional 3D shoe scanner, showing the dimensions of both feet, the height of the arch and the differences in the shape of the right and left feet.

This is already being used in stores - customers walk in from the street, scan their feet and the salesperson can tell them at a glance which shoes fit them, which ones fit perfectly, and let them try on the right ones straight away.

Customers in stores typically know their size, and retailers can compare their size with the scan results. Ecco shoes are usually slightly larger than models from other manufacturers in the same size.

The shoes are personalized as follows: Scan data is used as well as data from a second source - a special shoe with sensors that is given to the customer and asked to walk through it. The sensors transmit information about gait to the software: changes in foot position, changes in pressure at different parts of the foot while walking.

A special algorithm correlates the data from the scanner, the data from the gait sensors and the measurements to create a digital model.

HP and Superfeet: FitStation

FitStation is a project between Superfeet and HP. It is a solution for customizing shoes based on existing models and creating individual shoe insoles.

How it is done

The idea is this: the consumer comes to a special kiosk and enters the required data - such as gender, age, weight. Then the scanning process is carried out.

A special True Form 3D RSscan Tiger shoe scanner, or rather an HP Fitstation kit, is used for scanning.

First, each foot is scanned one after the other.

The customer places their foot in the scanner, where a 3D scan is made.

This creates an accurate digital model of the foot with its unique geometry and all dimensions.

The next step is the gait scan: The patient walks several times on a special measuring mat.

The result shows the dynamic load distribution when walking, how the foot moves and how the weight is distributed among the different parts of the foot to maintain balance.

The user then has to answer several questions from the program, such as: E.g.: the purpose of the order - whether it is for training or competition, how often and with what intensity the shoes are to be used, known problems with other shoes - where they usually fit, where they pinch.

3D printing of shoes

The main advantage of 3D printing shoes is that you can make them at home.

All you need to do is buy a high-quality printer, stock up on raw materials and supplies, and you can start your mini-business.

Making shoes with a 3D printer is possible for any advanced computer user. Of the required:

• Download the necessary software and 3D shoe models;
• Select the desired model and enter the required dimensions previously agreed with the customer;
• Turn on the printer and click the 'Print' button.

You will receive your new ergonomic trainer or shoe in no time. No assembly and sewing, no supinator gluing and no heel padding. The entire trainer is manufactured in one piece using the printer, making it durable and moisture-wicking. By extensively adjusting the values of the original model, you can create a shoe that fits your foot perfectly.

Custom made leather shoes. Complementary or core business

This type of shoe store focuses on small sales. High-quality leather shoes are not cheap, but in the domestic market they will be much cheaper than the corresponding EU products. The optimal solution would be to organize such production as an addition to the existing shoe business.

The production process of sewing exclusive leather shoes seems to be the most complex and is divided into several stages.

The first stage begins with the cutting workshop. Here the individual parts of the shoe are made from the previously prepared leather. This is done with the help of a stencil and special punches. The insole for the future shoe is also cut out here.

The material for the insole is first pressed into the desired shape, then the edges are sanded, the insole is pressed and glued together with special glue. The next step is to mark the insole. The seams and connections are traced. The finished pieces are then placed in the kiln to be fired, which softens the insert. This is essential for further work.

The next step is tailoring. It must be equipped with special machines with which the parts prepared in the previous steps are sewn together. The thermoplastic insoles are then glued and processed with a special machine before the sole is glued on. The sole itself is made of polyurethane or rubber. After gluing it to the shoe, the protruding parts are cut off with a knife. In the final phase, the finished shoe is polished with wax and laced.

How high are the costs?

The estimated initial cost is €400, but beforehand a pilot batch of 50 orders must be placed to collect user feedback. Finally, all the feedback we have now comes from Ecco employees, professional shoe testers and biomechanists at the University of Santa Barbara.

As long as it is a comfort product. Comfortable sports shoes become even more comfortable with these insoles and provide maximum support for a healthy foot.

If you need corrective shoes, you should consult an orthopedist, but if you are healthy and need shoes to reduce stress and fatigue, this is the right product.

In the future, when a manufacturer has medical partners or a licensed medical company acquires this solution and uses it in their business, the topic will grow.

How it is done

The idea is this: the consumer goes to a special kiosk, fills in the required data - such as gender, age, weight. Then the scanning process is carried out.

A special True Form 3D shoe scanner is used for scanning RSscan Tigeror a series of HP Fitstation.

First, each foot is scanned one after the other.

The customer places their foot in the scanner, where a 3D scan is created.

This creates an accurate digital model of the foot with its unique geometry and all dimensions.

The next step is a gait scan: The patient walks several times on a special measuring mat.

The result shows the dynamic load distribution when walking, how the foot moves and how the weight is distributed among the different parts of the foot to maintain balance.

The user must then answer a series of questions, including: the purpose of the order - whether the shoes are intended for training or competition, how often and with what intensity the shoes will be used, known problems with other shoes - where they usually fit where they pinch.

Based on all this information, the software suggests the best solution.

The way of making the insole

The method is based on the use of a flat semi-finished product for the manufacture of custom-made orthopedic insoles and semi-insoles, taking into account the size of the foot, existing deformities and the type of footwear worn by the patient. The base of the half insole consists of a special thermoplastic material that is deformable under the influence of temperature and can be molded directly to the patient's foot. The insole is made on a flat surface or on a last that simulates the position of the foot in a heeled shoe. It is more convenient to make the insole on a special Planterscope using a Heider gauge, which contains a set of insoles for different heel heights. If the patient wears shoes without a heel cap or with a heel cap of up to 3 cm, the insertion is carried out on a flat surface directly on the Heider measurement without the use of washers.

After examining the patient's foot, the type of semi-finished orthotic product is determined, taking into account the existing foot deformity and the type of footwear in which the patient will wear the insoles. The corresponding semi-finished product is then cut to the foot size. Heat the semi-finished product on the plantar side. Heat the insole with a special hairdryer.

The distance from the nozzle of the hairdryer to the middle part of the insole (the protrusion of thermoplastic material) is 5-7 cm. The sign that the blank is ready is its plasticity. The warmed blank is placed on the platform under the insole. A special elastic band is placed over the projection of the longitudinal arch, and an insert simulating the transverse arch is placed in the diaphyseal projection of the metatarsal.

The patient sits so that the shinbone is perpendicular to the platform surface. The assistant fixes the heel bone and the heads of the 1st and 5th metatarsals and brings the foot into a physiological position. The insole is modeled by stretching a rubber band over the shape of the surface of the sole of the foot.

What are the advantages?

Firstly, the highest production speed of approximately 30-40 minutes, which is an industry record.

Secondly, the foot can be individually modeled in a completely orthopedic position. This allows for the most individual approach to the problem.

Third, we can correct the process step by step. This feature is particularly effective and beneficial for children and adults with severe foot deformities.

Fourthly, there are aesthetic advantages as custom-made insoles can be made for fashion shoes with a heel height of up to 12 cm.

The company achieves insoles of the highest quality, which, combined with an affordable, comfortable price, results in an unbeatable effect.

The production of orthopedic insoles is based on the use of flat blanks made of a special thermoplastic material. Under the influence of temperature, it becomes as deformable as possible, so that the insole acquires the same shape as the foot. This material has all the necessary hygienic properties.

This effect is achieved by manufacturing the insole on a special plantoscope with a Heider measure, which includes a set of insoles for shoes with different heel heights. This means that if the patient wears shoes without heel pads or with a heel pad of up to 3 cm, the shoes are made directly based on the Heider measurement.

The type and size of the hemi-tissue is then determined based on the degree of foot deformity.

The material is heated with a special hair dryer to make it as environmentally friendly as possible. The thermoplastic is then fixed to the foot by pulling on a special rubber band.

In this way, the thermoplastic takes on the full shape of the sole of the foot through the fixation of the band.
Among other things, we ensure patient comfort. Manufacture of orthopedic insoles on the Plantoscope. Insoles for model shoes are modeled using a shoe last.

Contact

order from Custom orthopedic insoles are available from orthopedic practice Orthopedic shoe factory in St. Petersburg at the address: ul, Soyuz Pechatnikova Street, 14

Telephone: (812) 714-08-08

Monday - Friday: 8:45 a.m. - 5:00 p.m

Declaration of Conformity	Certificate of registration

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Benefits of custom insoles

Custom-made insoles have unique advantages over factory-made mass-produced products:

• They are fully adapted to the shape of the foot - they are tailored exactly to the foot of a specific person. These insoles replicate the shape of the arch of the foot down to the smallest detail. They fit tightly to the foot over the entire surface and thus properly distribute the shock load when walking. In addition, the product takes into account the physical activity and lifestyle of the customer, the condition of the spine and anatomical features, thereby enhancing the therapeutic effect of the insoles;
• they can be corrected – if a newly made custom insole causes pain, the shape of the insole can be corrected. This allows for maximum therapeutic effectiveness as the product is tailored precisely to the shape of the foot;
• They are made to fit your preferred footwear - the insole can be made to fit narrow football boots and classic shoes.

Who needs custom insoles and why?

There are certain groups of people who need special care for the health of their feet. Custom-made insoles are required:

• for competitive sports - athletes are exposed to increased physical strain and an off-the-shelf insole may not be sufficient. This requires a product that is stable yet flexible and prevents the occurrence or development of flat feet;
• when high-heeled shoes are worn regularly and for long periods of time - custom-made insoles follow the curvature of the foot in fashionable shoes and are made according to the customer's preferred heel height. Plus, they can be changed from one pair of shoes to another. This is a very convenient solution. Factory orthopedic insoles for modeling shoes are made for a medium heel height. They are also undersized and are called half-inserts;
• with varying degrees of foot deformity – the diagnosis of flat feet does not mean that the feet are deformed in a mirror image. Due to the nature of the body and physical demands, the pressure on each foot can be different. Prefabricated insoles are all the same and therefore cannot fully offer effective therapy. Individual orthotic insoles are made for each foot to match the deformity. This increases the effectiveness of the therapy;
• If your feet feel heavy or painful at the end of the day, or if you have aching pain in the lower leg muscles or ankle area, custom-made insoles will distribute the load correctly based on the characteristics of your feet. You can walk much longer distances and no longer have any discomfort in your feet at the end of the day;
• Age-related changes in the foot – as we age, the fat pad on the surface of the sole of the foot atrophies. The fat pad serves to protect the bones from dynamic stress. Without the protective fat pad, the heads of the metatarsal bones are exposed to pressure and the foot hurts when walking. This protects against pain;
• for large foot deformities – to reduce pain and discomfort in the form of blisters and abrasions;
• In children who have a genetic predisposition to flat feet. Custom-made insoles support the arch of the foot from childhood. This ensures the proper development of the foot and ankle.

Indications for use

Before prescribing, you should have an examination to determine whether you need it. Custom orthotics should be requested when the following indications are noted

• different length of the lower limbs;
• Gout;
• Diseases caused by trauma to the limbs;
• diabetic foot;
• flat feet;
• obesity, including pregnancy;
• heel spur;
• deviation of the first toe;
• pain in the foot, ankle and knee joints;
• Morton's neuroma - severe pain caused by thickening of the nerve in the foot.

To prevent foot deformity and long-term pain, use custom-made orthopedic insoles. Feel the changes the first time you try them on. We look forward to seeing you.

How orthoses work

The principle is to distribute the wearer's body weight to the existing anatomical conditions. Minimal stress is placed on the injured areas, which helps eliminate pain. The even load prevents the formation of a valgus foot, which occurs due to incorrect foot positioning when walking.

The foot can become deformed at any age, and almost anyone who walks a lot or carries heavy loads is at risk. Tailor-made orthopedic insoles for the individual needs of each individual - even for people who do not have foot problems. Uncomfortable footwear, an active lifestyle, and other causes increase the likelihood of them occurring in the future.

By using shoe insoles, several effects can be achieved:

• Increasing stability when standing and moving (running, walking);
• Improving blood circulation in the foot area;
• Arch support (longitudinal and transverse arches);
• Reducing pressure on the joints of the foot and spine;
• reduce the risk of developing musculoskeletal disorders.

Wearing insoles helps to improve overall well-being. At the end of the day, our customers' feet are significantly less tired than with standard mass-produced models.

Medical opinions on insoles for flat feet in adults

– The foot – it is the foundation, the basis of the musculoskeletal system, which not only influences the joints and the spine, but also explains the function of other organs, including brain function the orthopedist and traumatologist Vasiliy Ertzkin. – A deformation of the foot deforms the entire musculoskeletal system, which leads to displacement of the muscles, pinching of blood vessels and nerves – all the way to the cervical spine and head. This, in turn, can lead to impaired blood supply and the transmission of nerve impulses, the development of headaches, reduced attention and concentration, and irritability. The condition of the foot is therefore very important for optimal health, and orthotics play a big role in this.

This issue should be considered from childhood. Today, one in two children has some type of foot deformity, which can later lead to flat feet and other problems. That is why I recommend prophylactic orthopedic insoles made of a special soft material, which are selected after a thorough diagnosis and assessment of the condition of the foot.

I believe (and have tested it myself) that properly fitted insoles are essential for every adult, even if they do not have foot deformities, let alone severe flat feet. They can be worn from the age of 25, because at this age around 65 of the population already suffer from one or another deformity. The most important thing is to choose the insoles with the help of a doctor.

The most common mistake is believing that you can wear insoles for a few years and then your flat feet will go away. That's not the case. Orthotics must be worn constantly and throughout life, and they must be corrected or replaced regularly. They are the best way to maintain the musculoskeletal system.

Popular questions and answers

Is it possible to cure flat feet with orthoses and other popular questions are answered by orthopedic traumatologist Vasily Yertskin.

Can flat feet be cured with orthotics?

– In general, flat feet cannot be cured. It is a chronic illness. However, it is possible to significantly reduce pain, swelling and fatigue. It is also possible to slow the progression of foot deformity or flat feet. Unfortunately, it is not possible to stop the process completely as it is a complex deformity. That's why shoe insoles alone are not enough. A whole complex of measures is necessary: physiotherapy, manual techniques (from massage to osteopathy), physiotherapeutic methods, functional treatment methods 4.

Can shoe insoles cause damage?

- Yes you can. If they are fitted or made incorrectly, which is unfortunately not uncommon. If the doctor incorrectly recognized the foot pathology and carried out the correction incorrectly, insoles can also cause damage, lead to the development of pain syndrome, lead to further deformation, swelling, inflammation, and affect the entire musculoskeletal system.

Which shoes should you wear with orthotics?

– Choosing the ideal footwear is difficult. It must definitely be closed (semi-closed with an open toe is acceptable) and have a solid insole. Otherwise the insole will slip and cannot fully fulfill its function. The shoe should fit snugly and have an optimal ratio of flexibility and elasticity between the sole and forefoot. There should be no play in the shoe and the insole should not move to the side. Therefore, orthopedic insoles are not recommended for heavily worn shoes.

1. Development of orthopedic sports orthopedic technology. KE Ryabin, AV Fedorov, VV Epishev. UDC, 2012. https://cyberleninka.ru/article/n/razrabotka-tehnologii-ortopedicheskoy-sportivnoy-stelki/viewer
2. Clinical research. An innovative method for measuring the prolapse of the navicular bone when walking in shoes. Bevica Fonden, 2021. https://formthotics.ru/upload/iblock/c4a/c4ad5e837dfd58445fc71f19c721deea.pdf
3. Treatment of longitudinal flatfoot. ER Mikhnovich, AI Volotovsky, EL Talako, BA Podobed. BGMU. Minsk, 2004. http://rep.bsmu.by/bitstream/handle/BSMU/8719/Prodol_ploskostop.pdf?sequ
4. Foot deformity and plantar fasciitis: a morphofunctional relationship. Variants of foot pathology, an overview. Effectiveness of a personalized comprehensive combined approach with local injection therapy, UWT and tailored orthoses. VV Ertzkin. 2022. https://chondroreparant.ru/knowledge-base/vebinary/deformatsiya-stopy-i-plantarnyy-fastsiit-morfofunktsionalnaya-vzaimosvyaz-varianty-patologiy-stopy-o/

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