Monday, July 13, 2009
 
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Doctors of Chiropractic

 

Metatarsal Pads
Too much pressure on the ball of the foot can cause pain, nerve damage, and foot deformity. A metatarsal support reduces forefoot pressure by reditributing weight before the met heads. This offloading can relieve pain and prevent further damage to the foot.

             

An Orthotic with a metatarsal support can reduce more of the forefoot pressure altogether. This is done by loading body weight in the arch and just before the metatarsal heads. Selecting a neoprene full length top cover will also increase comfort by dramatically increasing the amount of cushion the met heads can push down into.

Depressions

Depressions help redistribute weight and offload hotspots, such as Charcot arthropathy, callouses, bunions and other ailments. This is a unique Archfitters service that allows a higher level of both comfort and support to people with these ailments.

With our expert Pedorthists and cutting edge software, we can make you the most accomodating orthotic. Our software allows us to see a 3D visualization of the orthotic before it is manufactured, giving us the ability to build it exactly to your individual specifications.

Heel Wedges


Wedges can be added under the heel of any arch support. It is very common to wedge the heel of an Orthotic to gain more control. Improving bad alignments can help ankles, knees, and lower back. We recommend you do not go above 6mm in wedges unless you have had experience using them or prescribe by your doctor. Wedges will change your alignment and can cause discomforts in the body for up to 30 days. These discomforts will fade as the body adjusts to its new alignment.

Heel Lifts


Heel lifts are added to one of the Orthotics to lift the heel. They are most commonly used when one leg is shorter than the other. Make sure you select the lift on the shorter leg. There are some cases were both heels are lifted such as Achilles pain and Plantar Fasciitis. When you raise both heels there is less strain on the calf muscle, attaching tendons, and the plantar fascia tissue. A wedge can also be added with a heel lift.

Top Covers

Grey Plastizote: Provides good cushion is an open cell foam that breathes well. It is a hypoallergenic material designed to be soft and comfortable for even sensitive skin. Most popular top cover for full length EVA and 3/4 plastic orthotics. Available in 2mm and 3mm thicknesses.
Naugahyde: Simulates a leather look and feel. It is long lasting and thin profiled to fit small volume shoes. The surface texture does not grip socks making it easier to get shoes on.
Sports Top: This is closed cell EVA foam designed for durability. Being closed celled makes this top cover waterproof and ideal for sports or work. Optimal for activities that requires durability agaianst perspiration, water and dirt. Not recommended for customers that require high shock absorbtion. Available in 1.5mm and 3mm thicknesses
Dual Cloth: Researched and developed with Hy-PUR-cel open-celled polyurethane foam technology. Ultra Low compression set makes this top cover have great shock absorption with increased life. Laminated with a breathable cloth top for comfort. Can be used on 3/4 and full length models. Available in 1.5mm, 3mm and 4.5mm thicknesses.
Dual Plastizote: A laminate of 3mm HyPUR-cel® and 2mm Plastizote. The double layer provides 5mm of total padding. Use this top cover when plastizote is needed for sensitivity and durability is needed. Available only in a 5mm thickness.
Dual Naugahyde: A laminate of 1.5mm HyPUR-cel® and 1mm Nogahide. Provides a very thin but durable top cover for low volume footwear. Available only in a 2.5mm thickness.

EVA Accomodating Foam

EVA(Ethylene Vinyl Acetate) is an orthopedic foam which is standard in the industry for making custom accommodating orthotics. It is also used in the soles of running shoes because of its cushion and durability. These orthotics are CnC machined from a patient’s cast.
 

Thickness


Each orthotic is milled out with a standard 3mm base. Base means the thickness of material on the toe area before a top cover is added. An orthotic with a 3mm base and a 3mm top cover will have 6mm total thickness. Try to match the total thickness ordered with the footwear it will be worn in. For example, most athletic shoes have a removable insole that measures close to 6mm thick. Casual shoes commonly only have a 3mm removable insole, while dressier shoe may only have 2mm or no removable insole. Customer satisfaction is hard to maintain when ordering a 6mm thick orthotic to fit into footwear that only has room for 3mm. A specific base layer can be requested in the notes to over ride the 3mm default value. Ordering a soft density with a thicker base such a 5mm will increase comfort and durability. Decreasing the base thickness in a firm density to 1mm will produce a much thinner orthotic. It is not recommended to order a soft Eva with less then 3mm or a firm Eva thicker then 3mm. Here are some examples of our program and its custom options.

Density

  • Soft Eva-45 Durometer  

    • Very soft with good support
       
    • Durable for 4 months.
       
    • Accommodates sensitive feet.
       

  • Medium Eva-55 Durometer  

    • Most popular density for good support and durability.
       
    • Durable for 1 Year.
       
    • Great for everyday use and moderate alignment changes.
       

  • Hard Eva-65 Durometer  

    • Excellent support with long life of 2 years.
       
    • Maximum alignment control with shock absorption.
       
    • Delivers great control with wedges and heel lifts.

Plastic Thickness

1/8" Plastic: used when a flex is desired. Select this thickness for dressier shoes or when a rigid arch is not desired. You will gain increased support in shoes but not overwhelming pain from an aggressive arch support. Works great for runners who want to increase support but still want the arch to flex. Recommended for body weight up to 140 lbs.		  

3/16" Plastic: used when arch support is the main focus. For most people this thickness will prevent the arch from dropping. It is the normal thickness for orthopedic devices especially for treating Plantar Fasciitis. This thickness maintains solid support for up to 180 lbs or a men’s shoe size 12. After that some mild flex will occur but still offer great support.

1/4" Plastic: used for maximum support. Has no flex in the arch. Recommended for body weight of more than 220 lbs or shoe sizes larger than men’s 13.

Graphite

Graphite: is the strongest support we offer. Multiple sheets of graphite are used to offer the most firm orthotic possible. Lasts up to 5 years!

 
 

 

 
 

Bio-Foam Foot Casting Kit

Foot Casting

Before we begin manufacturing, we need an accurate foot shape to process. Many internet orders and low volume facilities like the easy and low cost solution of Bio-Foam casting kits. Arch Fitters will supply all internet orders with a free kit. Larger volume facilities love the speed and accuracy of our digital scanner. We are proud of our reputation of being one of the fastest central manufacture labs in the USA.

Programming

Designing the shape and function of each orthotic takes years of experience using our state of the art software, Solid Works. Each orthotic is programmed by one of our senior orthotic designers using this extremely accurate modeling program, Solid Works to achieve accuracy. Wedges, heel lifts, Metatarsal supports, and other options are programmed with precision. Each orthotic has 900 control points for infinite manipulation.


Click here for more info

Computer Control Machine Cutting

In simple terms we start with a full sheet of Ethylene Vinyl Acetate (EVA) roughly 1 ½ inches thick. The computer carves out the EVA to the exact 3D shape derived by Solid Works. The amazing part is, our CnC machines must execute 1200 movements to cut out each orthotic. With this many movements each orthotic comes out smooth and accurate each time.

Top Covering

In the final stage a top cover is added and the orthotic is trimmed to the selected shoe size. There are many top covers to select from each having a unique purpose. Detail descriptions can be viewed by clicking here. After the orthotic has been completed and inspected for quality assurance, it is then mailed out. This entire process takes about 24 hours. Once we get your cast via mail or electronic upload, Arch Fitters will manufacture and ship within 24 hours.


 

 

 

   

Bio-Foam Casting Kit

Foot Casting

Before we begin manufacturing, we need an accurate foot shape to process. Many internet orders and low volume facilities like the easy and low cost solution of Bio-Foam casting kits. Arch Fitters will supply all internet orders with a free kit. Larger volume facilities love the speed and accuracy of our digital scanner. We are proud of our reputation for being one of the fastest central manufacture labs in the USA.

Programming

Designing the shape and function of each orthotic takes years of experience using our state of the art software, Solid Works. Each orthotic is programmed by one of our senior orthotic designers using this extremely accurate modeling program. Solid Works to achieve accuracy. Wedges, heel lifts, Metatarsal support, and other options are programmed with precision. Each orthotic has 900 control points for infinite manipulation.


Click here for more info

 

Vacuum Forming

After the orthotic is designed, a wooden mold is cut out. A mold is a hard representation of a person’s foot with corrections. The corrections are necessary to medically align the foot and help heal, correct, or comfort each unique foot concern. Once the mold is finished it is prepped and put into a vacuum bladder system. This system is commonly known as vacuum forming. A layer of plastic, graphite, or EVA will form over these molds. In most cases the material is heated up to a certain temperature that allows it to be flexible. It is at this point the rubber bladder is closed and all air is sucked out of the unit. This causes the top rubber bladder to form over the molds forcing the material to take thier new shape. Once the heated material cools long enough the new shape becomes permanent. Thicker plastic and graphite takes longer to form.

Top Covering

Once you remove the formed plastic or material from the mold, there is a lot of excess plastic. This material needs to be removed from the orthotic or it will not fit into shoes. After the shape and profile is achieved, each orthotic is hand buffed to remove any jagged edges or rough spots. Reshaping the orthotics takes great skill and artistic abilities. Taking something that is ugly and making it beautiful is something very few people can do. Arch Fitters is proud to have production staff that takes pride in their work. The products are of such a high quality that some people can’t believe our products are hand made because they look too good.

In the final stage a top cover is added and the entire orthotic is trimmed to the selected shoe size. There are many top covers to select from, each having a unique purpose. Detailed descriptions can be viewed by clicking here. After the orthotic has been completed and inspected for quality assurance, it is then mailed out. This entire process takes about 24 hours. Once we get your cast via mail or electronic upload, Arch Fitters will manufacture and ship within 24 hours.

 
 

 


 
 




Become an Arch Fitters casting clinic!

  • Proven Chiropractic Network
  • We VERIFY Insurance Benefits
  • NO Minimums
  • No Hassles
  • Experienced Orthotic Lab Team

 

 



Our Process

Step 1 - Evaluate your patient and determine whether an orthotic will benefit their diagnosis, alignment and quality of life.


Step 2 - Fill out our simple Evaluation and Prescription forms. Explain to the patient that their casting and forms are being submitted to our Orthotic Lab Review Team. Castings can be submitted with a FOAM BOX cast or electronically with our 3D Computer Scanning Process.


Step 3 - We will review their casts and verify insurance coverage within 24 hours of receiving your package. An Arch Fitters expert, at no expense, will then contact you to determine which orthotic will best serve your patient's needs.


Step 4 - Arch Fitters will then produce the Custom Orthotic within 24 hours and mail it directly to you. Each mailing will include instructions on how to begin wearing them and a support phone number if you encounter any questions or problems. Arch Fitters is responsible in completely satisfying your patients with our popular guarantee.



Contact Dr. Kim Christensen for any further questions at dcinfo@archfitters.com.


 

 

 

 
 
 
 
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