Kevin Orthopedic Clinic Prescribing Guide

ED BIOMEC Clinical
SOLUTIONS Foot Orthotic
Prescribing Guide

• ADVANC HANICAL • -

Foot Impression Methods Supination Corrections
Frame Fabrication Methods Extensions

Orthotic Devices Offloading Pads & Cushions
Materials Frame Modifications

Pronation Corrections Complete Orthotic Line



Kevin Orthopedic has received feedback from partnering
clinicians to develop a prescribing guide and ordering
experience that allows the clinician to provide the highest
quality foot orthotic outcomes for patients.
This essential guide is for the community of clinicians whose
mission and ambition is improving life performance for patients.
Experience why clinics across the globe are ecstatic about
partnering with Kevin Orthopedic.
Welcome to the new wave of orthopedic outcomes.
Prescribe Better.

Our focus is foot function.
Thank you for partnering with us.

Kevin B. Rosenbloom, C.Ped
Founder, Sports Biomechanist

Content enclosed is the intellectual property of Kevin Orthopedic.
Use and replication without permission is strictly prohibited.

 Table of Content



Table of
Contents

4.

Table of Contents 

1 Clinician Information. . . . . . . . . . . . . . . . . . . . . . 9 B Pronation Corrections

2 Patient Information . . . . . . . . . . . . . . . . . . . . . . . . 9 Balance Forefoot to Rearfoot . . . . . . . . . . . . . . . . . . . . . . 65
Varus Extrinsic (Bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3 Impression, Fabrication & Optimization Varus Metatarsal Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Raise Medial Arch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Foot Impression and Frame Fabrication Methods. . . . . . 11 Scaphoid Pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Lab Standard Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Varus Cuboid Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Plaster Slipper Cast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Medial Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Foam Impression. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Varus Intrinsic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
STS Slipper Sock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Varus Extrinsic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3D Foot Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Heel Skive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Pedobarography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Existing Positive Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 C Supination Corrections
Redimold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Plaster Positive Model Vacuum Formed . . . . . . . . . . . . . 20 Balance Forefoot to Rearfoot . . . . . . . . . . . . . . . . . . . . . . 77
CAD CAM Positive Model Vacuum Formed . . . . . . . . . . 21 Valgus Extrinsic (Bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3D Printed Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Valgus Metatarsal Wedge . . . . . . . . . . . . . . . . . . . . . . . . . 79
Direct Mill Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Lower Medial Arch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Redimold Positive Model Vacuum Formed . . . . . . . . . . . 24 Lateral Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Order Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Valgus Frame Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Orthosis Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Valgus Cuboid Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Valgus Intrinsic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4 Orthotic Devices Valgus Extrinsic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

A1 Pro Sport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 D Extensions
A7 Pro EVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A3 Classic Sport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Toe Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
A4 Subo-Flex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Morton’s Extension to Toes . . . . . . . . . . . . . . . . . . . . . . . . 88
L3 Ultra Slim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Reverse Morton’s Extension to Toes . . . . . . . . . . . . . . . . 89
L7 Cobra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Dynamic Wedge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
L4 Subo-Flex LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Sulcus Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
L1 Fashion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Morton’s Extension to Sulcus . . . . . . . . . . . . . . . . . . . . . . 92
T4 UCBL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Reverse Morton’s Extension to Sulcus. . . . . . . . . . . . . . . 93
T9 EVA UCBL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Foot Cookie Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
T6 Pediatric UCBL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Toe Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
T5 Modified UCBL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
T2 Care Firm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 E Offloading Pads & Cushions
T1 Care Soft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
T7 Diabetic Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Metatarsal Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
T3 Premium Diabetic . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Metatarsal Punch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Metatarsal Pad 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
A Materials Metatarsal Bar 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Dancer’s Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Top Cover Cuboid Offload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Covering and Frame Material Options . . . . . . . . . . . . . 47 Heel Cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Prolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Heel Spur Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Spenco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Myolite Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Protex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Plastazote Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Glove Leather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Suede . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 F Frame Modifications
Plastazote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Glue Only Heel of Cover for Placing Pads in Clinic . . . . 53 1st Ray Cut Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5th Ray Cut Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Bottom Cover Navicular Button Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Suede. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 5th Button Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Suede Bottom Wrap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Heel Aperture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Protex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Heel Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Myolite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Frame Filler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Filler Skive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Frame Options Heel Cup Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Frame Calibration Guide Per Weight . . . . . . . . . . . . . . 58 Width of Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Frame Material Rigidity Guide . . . . . . . . . . . . . . . . . . . . 58 Device Undercut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Polypropylene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Detached Carbon Foot Plate to Toes. . . . . . . . . . . . . . . . 118
Subortholene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Complete Orthotic Line
TPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
EVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 All Foot Orthotic Devices . . . . . . . . . . . . . . . . . . . . . . 121-127

Section: 1 2 3 4 A

Starts at: Page 9 Page 9 Page 10 Page 28 Page 46

Professional Foot Orthotic Rx Download PDF Rx at www.kevinorthopedic.com/rx

Page 1 REQUIRED Professional Foot Orthotic Rx 1 OF 2

9 .....  CLINICIAN

Account Location Date: / /
PO Number MM DD YYYY
Clinician
Clinician Email Rush order due date:

// YYYY Call us: 1-877-767-3338
MM DD Fax: 1-866-919-9268

Contact me to review Rx www.kevinorthopedic.com
[email protected]

9 .....  PATIENT 2 REQUIRED

Patient’s Email Ship to Patient
Street Address
First Name
City
Last Name

DOB / / Sex: M F Weight Height Shoe Size State Zip
MM DD YYYY

10 - 27  FOOT IMPRESSION METHOD 3 REQUIRED OPTIMIZATION

Plaster Slipper Cast 3D Foot Scanner Redimold: Bilateral (Asymmetrical) Fit Orthosis to submitted:
Normal Mirror Right Tracing
Foam Impression Pedobarography Planus Mirror Left Insoles
Cavus Shoes
STS Slipper Socks Digitize model Existing Positive Right Only
Store model for 3 months Model
Left Only
Return model

 FOOT ORTHOTIC SELECT ONE PER ORDER FORM 4 REQUIRED

29 . . . . . A1 Pro Sport - Poly frame, 12mm heel cup, RF EXT post, 1.5mm myolite extension, 2mm prolite T/C, suede B/C, cover to toes

30 . . . . . A7 Pro EVA - EVA frame, 12mm heel cup, RF INT post, 1.5mm myolite extension, 1.5mm spenco T/C, suede B/C, cover to toes

31 ..... Active A3 Classic Sport - Poly frame, 12mm heel cup, RF EXT post, no extension, .75mm protex T/C, no B/C, cover to mets
32 . . . . . A4 SuboFlex - Subo frame, EVA frame fill, 12mm heel cup, RF EXT post, 1.5mm myo ext, 1.5mm spenco T/C, suede B/C, cover to toes

34 ..... L3 Ultra Slim - Carbon frame, 6mm heel cup, narrow width, rearfoot intrinsic post, protex top cover, suede wrap bottom cover

35 . . . . . L7 Cobra - Subo frame, narrow width, 6mm heel cup, EVA cobra frame fill, RF INT post, no extension, .75mm protex T/C, no B/C, cover to sulcus

36 . . . . . Dress L4 Suboflex LP - Subo frame, narrow width, 6mm heel cup, EVA frame fill, RF INT post, no extension, .75mm protex T/C, no B/C, cover to sulcus
37 ..... L1 Fashion - Poly frame, narrow width, 6mm heel cup, RF INT post, suede top cover, suede wrap B/C, cover to mets

38 ..... T4 UCBL - Subo frame, wide width, 24mm heel cup, high medial/lateral flanges, RF EXT post, .75mm protex T/C, no B/C, cover to mets

39 . . . . . T9 EVA UCBL - EVA frame, EVA frame filler, 24mm heel cup medium medial/lateral flanges, RF INT post, .75mm protex T/C, no B/C, cover to mets

40 . . . . . UCBL T6 Pediatric UCBL - Poly frame, wide width, 18mm heel cup, high medial/lateral flanges, RF EXT post, .75mm protex T/C, no B/C, cover to mets
41 ..... T5 Modified UCBL - Subo frame, wide width, 12mm heel cup, medium medial/lateral flanges, RF EXT post, .75mm protex T/C, no B/C, cover to mets

42 . . . . . T2 Care Firm - Poly frame, wide, 12mm H/C, RF EXT post, 1.5mm myo ext, 3mm plastazote cushion, G. leather T/C, Suede B/C, cover to toes

43 ..... T1 Care Soft - Cork frame, EVA frame fill, 12mm H/C, RF INT post, 1.5mm myo ext, 3mm plastazote cushion, G. leather T/C, Suede B/C, cover to toes

44 ..... T7 Diabetic Inserts - Pairs: 1 2 3 - EVA Frame, Plastazote T/C, multi-density, total contact with patient’s foot, cover to toes
Therapeutic T3 Premium Diabetic - EVA frame, EVA frame fill, 12mm H/C, RF INT post, 1.5mm myolite extension, 3mm plastazote T/C, cover to toes

45 . . . . .

46 - 63  MATERIALS A OPTIONAL

Length of Cover: To Mets To Sulcus To Toes FRAME Flexible Semi Semi Rigid Very Most
Flexible Rigid Rigid Rigid
PolyPro mm 4 5 6
TOP Prolite  2  3 (mm) Spenco  1.5  3 (mm) Protex  0.75 (mm) Subo mm N/A 2  3 4 5  N/A
COVER Plastazote  0.75 (mm) Carbon mm 3 2.5 
BOTTOM Glove Leather  1 (mm) Suede  0.6 (mm) TPE mm N/A 2  2 N/A 3  3 TL 
COVER EVA Shore A N/A 65  N/A N/A
 Glue only heel of top cover for placing forefoot pads in clinic N/A 1.5  45  N/A N/A

Suede  0.6 (mm) Suede Bottom Wrap  0.6 (mm) 3 4
Protex  0.75 (mm) Myolite  1.5  3 (mm)
15  30 

Special Instructions/Special Device:

Section: B C D E F

Starts at: Page 64 Page 76 Page 86 Page 96 Page 106

Professional Foot Orthotic Rx Download PDF Rx at www.kevinorthopedic.com/rx

 PATIENT Plantar Professional Foot Orthotic Rx 2 OF 2
View
First Name RT LT Date: / /
Last Name
B MM DD YYYY

PRONATION CORRECTIONS - RIGHT C LEFT - PRONATION CORRECTIONS---- Page

Varus Balance FF to RF 8°  6°  4°  2°  90° D 90° 2°  4°  6°  8°  Balance FF to RF Varus . . . . . 65
Forefoot VR Extrinsic (Bar) 6°  4°  2°  0°  0°  2°  4°  6°  VR Extrinsic (Bar) Forefoot . . . . . 66
6°  4°  2°  E 2°  4°  6°  VR Met Wedge Posts . . . . . 67
Posts VR Met Wedge (mm) 1.5  3  4.5  6  . . . . . 68
6  4.5  3  1.5  (mm) F (mm) 1.5  3  4.5  6  . . . . . 69
Raise Med Arch 6  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  6  Raise Med Arch . . . . . 70
6  4.5  3  1.5  (mm) Low  Medium  High  . . . . . 71
Midfoot Scaphoid Pad Scaphoid Pad Midfoot . . . . . 72
VR Cuboid Pad High  Medium  Low  0°  2°  4°  6°  VR Cuboid Pad . . . . . 73
0°  2°  4°  6°  . . . . . 74
Medial Flange (mm) 2  4  6  Medial Flange

Varus VR Intrinsic 6°  4°  2°  0°  VR Intrinsic Varus
Rearfoot VR Extrinsic 6°  4°  2°  0°  VR Extrinsic Rearfoot
Heel Skive Posts
Posts Heel Skive 6  4  2  (mm)

SUPINATION CORRECTIONS - RIGHT LEFT - SUPINATION CORRECTIONS----

Valgus Balance FF to RF 8°  6°  4°  2°  90° 90° 2°  4°  6°  8°  Balance FF to RF Valgus . . . . . 77
Forefoot VG Extrinsic (Bar) 6°  4°  2°  0°  0°  2°  4°  6°  VG Extrinsic (Bar) Forefoot . . . . . 78
6°  4°  2°  2°  4°  6°  VG Met Wedge Posts . . . . . 79
Posts VG Met Wedge (mm) 1.5  3  4.5  6  . . . . . 80
6  4.5  3  1.5  (mm) Low  Medium  High  . . . . . 81
Lower Med Arch High  Medium  Low  0°  2°  4°  6°  Lower Med Arch . . . . . 82
6°  4°  2°  0°  (mm) 1.5  3  4.5  6  . . . . . 83
Midfoot Lateral Flange 0°  2°  4°  6°  Lateral Flange Midfoot . . . . . 84
VG Frame Filler 6  4.5  3  1.5  (mm) 0°  2°  4°  6°  VG Frame Filler . . . . . 85
6°  4°  2°  0° 
VG Cuboid Pad 6°  4°  2°  0°  VG Cuboid Pad

Valgus VG Intrinsic VG Intrinsic Valgus
Rearfoot Posts VG Extrinsic VG Extrinsic Rearfoot Posts

EXTENSIONS - RIGHT LITE LEFT - EXTENSIONS----

Toe Extension 4.5  3  1.5  (mm) (mm) 1.5  3  4.5  Toe Extension . . . . . 87

Toe Morton's Ext. U.skiv  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  U.skiv  Morton's Ext. Toe . . . . . 88
Length Rev. Morton's U.skiv  4.5  3  1.5  (mm)
(mm) 1.5  3  4.5  U.skiv  Rev. Morton's Length . . . . . 89

Dynamic Wedge 3  1.5  (mm) (mm) 1.5  3  Dynamic Wedge . . . . . 90

Sulcus Extension 4.5  3  1.5  (mm) (mm) 1.5  3  4.5  Sulcus Extension . . . . . 91

Sulcus Morton's Ext. U.skiv  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  U.skiv  Morton's Ext. Sulcus . . . . . 92
Length Rev. Morton's U.skiv  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  U.skiv  Rev. Morton's Length . . . . . 93

Foot Cookie Ext. 4.5  3  1.5  (mm) (mm) 1.5  3  4.5  Foot Cookie Ext. . . . . . 94

Partial Foot Toe Filler Toe Filler   5th  4th  3rd  2nd  1st  1st  2nd  3rd  4th  5th  Toe Filler   Partial Foot Toe Filler ..... 95

OFFLOADING PADS & CUSHIONS - RIGHT LEFT - OFFLOADING PADS AND CUSHIONS----

Met Balance   5th  4th  3rd  2nd  1st  1st  2nd  3rd  4th  5th    Met Balance . . . . . 97
5th  4th  3rd  2nd  1st  1st  2nd  3rd  4th  5th  . . . . . 98
Met Punch   (mm) 1.5  3  4.5    Met Punch . . . . . 99
4.5  3  1.5  (mm) (mm) 1.5  3  4.5  . . . . . 100
Forefoot Met Pad 2-4 4.5  3  1.5  (mm) (mm) 1.5  3  4.5  Met Pad 2-4 Forefoot . . . . . 101
4.5  3  1.5  (mm) (mm) 1.5  3  4.5  6  . . . . . 102
Met Bar 1-5 6  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  6  Met Bar 1-5 . . . . . 103
6  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  6  . . . . . 104
Dancer's Pad 6  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  Dancer's Pad . . . . . 105
4.5  3  1.5  (mm) (mm) 1.5  3  4.5  6  . . . . . 105
Midfoot Cuboid Offload 6  4.5  3  1.5  (mm) Cuboid Offload Midfoot

Rearfoot Heel Cushion Heel Cushion Rearfoot
Heel Spur Pad Heel Spur Pad

Device Length Layer Layer Device Length
Plastazote Layer Cushion
Cushion Plastazote Layer

FRAME MODIFICATIONS - RIGHT LEFT - FRAME MODIFICATIONS----

Forefoot 1st Ray Cut Out Full  65°  45°  45°  65°  Full  1st Ray Cut Out Forefoot . . . . . 107
5th Ray Cut Out 65°  45°  45°  65°  5th Ray Cut Out . . . . . 108

Midfoot Navicular B. Out 6  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  6  Navicular B. Out Midfoot . . . . . 109
5th Button Out 6  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  6  5th Button Out . . . . . 110

Heel Aperture With Visco Plug  No Plug  No Plug  With Visco Plug  Heel Aperture . . . . . 111

Rearfoot Heel Lift 6  4.5  3  1.5  (mm) (mm) 1.5  3  4.5  6  Heel Lift Rearfoot . . . . . 112

Heel Lift Tapered 26  22  18  14  10  (mm) (mm) 10  14  18  22  26  Heel Lift Tapered . . . . . 112

Frame Attributes Frame Filler Rigid  Semiflexible    Semiflexible  Rigid  Frame Filler Frame Attributes ..... 113

Filler Skive Max  Med.  Min.  None  None  Min.  Med.  Max  Filler Skive . . . . . 114

Heel Cup Depth 30  24  18  12  6  (mm) (mm) 6  12  18  24  30  Heel Cup Depth . . . . . 115
Width of Frame Wide  Standard  Narrow 
Narrow  Standard  Wide  Width of Frame . . . . . 116

Device Undercut 30°  20°  15°  10°  0°  0°  10°  15°  20°  30°  Device Undercut . . . . . 117

Detached Carbon Foot Plate to Toes Rigid  Semi-rigid  Semi-rigid  Rigid  Detached Carbon Foot Plate to Toes ..... 118

Special Instructions/Special Device:

1 Clinician & Patient Info

12

Clinician &
Patient Information

The following two sections of the Rx are required for
accurate identification.

8.

Clinician & Patient Information 1

Section 1 - Clinician Information

Please complete both sections thoroughly and legibly to ensure order
accuracy. If there are multiple clinical locations, please specify which location
to return the order. Any account or clinician updates can be made online at
www.kevinorthopedic.com or email [email protected]

 CLINICIAN 1 REQUIRED

Account Location
PO Number
Clinician Contact me to review Rx
Clinician Email Select this option and a
technician will reach out before
Rush order due date: Consider transit time when calculating rushes. an order is processed.
Please visit www.kevinorthopedic.com or
// YYYY email [email protected] to learn Note: Pictures and videos of
MM DD more about rush services. a patient’s needs are always
helpful to share with the lab.

Section 2 - Patient Information

 PATIENT 2 REQUIRED

Patient’s Email Ship to Patient

First Name Street Address

Last Name

DOB / / Sex: M F Weight Height Shoe Size City State Zip
MM DD YYYY

Patient DOB, sex, weight, height and shoe Fill out this field if a patient
size are required for optimal lab results. This would like to receive an order
information is used for frame calibration and directly at an additional cost.
finished covering length.

9.

3

Impression,
Fabrication &
Optimization

Kevin Orthopedic accepts all clinical impression methods
and utilizes a variety of frame fabrication techniques.

Foot Impression and Frame Fabrication Methods 3

 FOOT IMPRESSION METHOD 3 REQUIRED OPTIMIZATION

Plaster Slipper Cast 3D Foot Scanner Redimold: Bilateral (Asymmetrical) Fit Orthosis to Submitted:
Normal Mirror Right Tracing
Foam Impression Pedobarography Planus Mirror Left Insoles
Cavus Shoes
STS Slipper Socks Digitize model Existing Positive Right Only
Store model for 3 months Model
Left Only
Return model

Foot Impression Methods and Orthotic Congruent Accuracy Rating
Frame Fabrication Methods
 variation 2-5%
There are 7 common methods for capturing a patient’s foot contour: Plaster Slipper Cast, Foam  variation 6-9%
Impression, STS Slipper Sock, 3D Scan, Pedobarography, Positive Model and Redimold. There  variation 10-13%
are 5 different lab methods for orthotic frame fabrication: Plaster Positive Model Vacuum Formed,  variation 14-17%
CAD CAM Positive Model Vacuum Formed, 3D Printed Frame, Direct Mill Frame and Redimold  variation 18-21%
Vacuum Formed. Tolerances in foot impression methods and fabrication methods produce variable  variation 22-25%
outcomes for how similarly the orthotic frame matches the patient’s foot. The chart below shows  variation 26-29%
outcomes of shape-contour variation between foot, foot-model and orthotic frame when different  variation 30-33%
methods are combined. Congruent accuracy is a measure of how closely the orthotic frame  variation 34-37%
matches the patient’s foot in the exact position the patient’s foot impression was captured.  variation ≥38%

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 [email protected]

ORTHOTIC FRAME FOOT IMPRESSION METHOD
FABRICATION
METHOD (CLINICIAN PROCESS)

(LAB PROCESS) Plaster Foam Existing STS Slipper 3D Foot Redimold
Slipper Cast Impression Positive Sock Scanner Pedobarography 0% variation*
2% variation 2% variation Model 1% variation 15% variation (shoe size &
1% variation 10% variation
 arch height)
 
Plaster Positive Model  4% N/A N/A N/A
Vacuum Formed (lab standard) 3% 12%
2% variation 4% (lab standard)  N/A N/A
(lab standard)  
CAD CAM Positive Model  11%
Vacuum Formed  12% 20% (lab standard)
10% variation 11% (lab standard)
12%

3D Printed Frame      N/A N/A
7% variation
9% 9% 8% 17% 8%

Direct Mill Frame      N/A N/A
18% variation
20% 20% 19% 28% 19%

Redimold Positive Model *     *     *     *     *     *     *    
Vacuum Formed
4% 4% 3% 12% 3% 17% 2%
2% variation
(lab standard) (lab standard)

* 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.

11.

3 Lab Standard Methods

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

FOOT IMPRESSION METHODS FRAME FABRICATION METHODS FOOT MODEL DATA
(LAB STANDARD*) (LAB STANDARD*)

Plaster Slipper Cast Plaster Positive Model Model storage for 3 months
Vacuum Formed (return positive model optional)

Foam Impression Plaster Positive Model Model storage for 3 months
Vacuum Formed (return positive model optional)

STS Slipper Socks CAD CAM Positive Model Stored indefinitely
Vacuum Formed
Stored indefinitely
3D Foot Scanner CAD CAM Positive Model
Vacuum Formed

Pedobarography Redimold Positive Model Stored indefinitely

Existing Positive Model Vacuum Formed Positive model
returned to clinic

Redimold Redimold Positive Model Stored indefinitely

* 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 [email protected]

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:

Kevin Orthopedic 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, Kevin Orthopedic 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.
12.

Foot Impression Method - Clinician Process 3

Plaster Slipper Cast 2% FOOT TO IMPRESSION
VARIATION TOLERANCE
Gold standard of impression methods
ADVANTAGES
SUBMIT ORDER • Yields an accurate and precise foot impression
Ship plaster cast with completed order • Ease of aligning the foot
form to laboratory1
DISADVANTAGES
STANDARD LAB PROCESS • Time-consuming
Plaster Positive Model Vacuum Formed • Messy
(CAD CAM Positive Vacuum Formed
optional)  CLINICAL PEARL
To achieve a balanced cast, suspend foot with heel, 1st
FOOT MODEL DATA and 5th metatarsal heads in level plane while achilles
Model storage for 3 months (return tendon is plumb-lined with Anterior Superior Iliac Spine.
positive model optional)

1 234

Find neutral hip position by internally Prepare plaster splints, gauze and Dip and wring out splint. Place moist splint extending from 1st
and externally rotating hip. water. 7 met head around heel to 5th met head.

5 6 8

Fold splint over center to seal up Push extra plaster over the Moisten and hang the 2nd splint over With one finger under the splint, fold
the bottom of the cast. back of the heel. toes. 1/3 above, 2/3 below the toes. one side over and then the other.

9 10 11 12

With finger rub cast into the contours Place the gauze over the sulcus and Suspend foot with heel, 1st and 5th After plaster is hard pull the skin
of the foot leaving with a smooth finish. interspace of the 4th and 5th toes. metatarsal heads plantigrade while away from the plaster.
achilles tendon is plumblined with ASIS.
13 14 15 16

Gently pull top of cast straight Carefully slide cast forward Inspect that the plantar surface has Ship cast impression when dry
down. and off the foot. made a smooth mold of the foot. and pack carefully.1

Note: All illustrations and diagrams are of right foot 13.
1 Print FedEx labels at www.kevinorthopedic.com/fedex

3 Foot Impression Method - Clinician Process

Foam Impression 2% FOOT TO IMPRESSION
VARIATION TOLERANCE
Quick, simple and accurate
ADVANTAGES
SUBMIT ORDER • Yields an accurate and precise foot impression
Ship impression foam with • Captures the foot’s natural fat pad expansion
completed order form to laboratory1 • Fastest capture of patient’s foot impression

STANDARD LAB PROCESS DISADVANTAGE
Plaster Positive Model Vacuum • Casting method is difficult to master
Formed (CAD CAM Positive Vacuum
Formed optional)  CLINICAL PEARL
To achieve a balanced impression, impress foot with heel, 1st
FOOT MODEL DATA and 5th metatarsal heads plantigrade while achilles tendon is
Model storage for 3 months (return plumb-lined in sagittal plane with Anterior Superior Iliac Spine.
positive model optional)
3
12

Ensure chair height will allow foot to sit level on Place plantar surface of heel on impression Grasp anterior ankle, stabilize STJ and hold
ground surface. Find neutral position for hip, foam directly under the center mass of knee. achilles tendon vertical. Push heel to the bottom
lower extremity joints and bone segments. Ensure foot is in middle of foam impression. of foam using contralateral hand atop of knee.

4 5 6

Distribute hand force and push the styloid and Push 1st metatarsal heads to bottom of foam Starting at the 5th toe, plantarflex all
5th ray to the bottom of foam. Then, pendulum in a similar motion allowing the TN and metatarsal heads 5-1 until distal phalanges
the tarsometatarsal joints in plantarflexion until tarsometatarsal joints to articulate naturally. are at bottom of foam.
metatarsals 5-2 are at the bottom of foam.
8 9
7

Grasping and stabilizing STJ, push styloid Carefully lift foot superior, heel first out of Inspect impression, look for neutral heel impressions
again to the bottom of the foam impression. the impression foam. with lateral and medial edges at the same height.
The heel, 1st and 5th metatarsal heads should all be
14. plantigrade. Often the arches will be higher than
desired. In these cases, reposition the foot and push
impression foam lower. The contour shape should
closely represent the desired congruency for the
orthotic frame. Pack foot impression with tissue paper
to maintain structure while shipping. Print FedEx
shipping label at www.kevinorthopedic.com/fedex

Note: All illustrations and diagrams are of right foot
1 Print FedEx labels at www.kevinorthopedic.com/fedex

Foot Impression Method - Clinician Process 3

STS Slipper Sock

Innovative non-weightbearing impression method 10% FOOT TO IMPRESSION
VARIATION TOLERANCE

SUBMIT ORDER ADVANTAGES

Ship slipper cast with completed order • Quick capture of patient’s foot impression

form to laboratory1 • Clean

STANDARD LAB PROCESS DISADVANTAGE
CAD CAM Positive Model Vacuum • Large variation congruency in gaps between foot
Formed (Plaster Positive Model Vacuum
Formed optional) impression sock and skin

FOOT MODEL DATA  CLINICAL PEARL
Stored indefinitely To achieve a balanced impression, suspend foot with heel,
1st and 5th metatarsal heads in level plane while achilles
tendon is plumb-lined with Anterior Superior Iliac Spine.

1 234

Slip bag over foot. Submerge Squeeze out excess water and Pull up sock around the heel. Attach one end of slipper clip
sock in cool water or hold under slip sock over bag. 6 at apex of medial arch below
running water. elastic band.

5 7

While maintaining tension of the strip and placement on the medial clip, Hold foot in neutral or desired Release slipper clip by twisting
gently pull up on the lateral clip to draw the elastic band across the dorsum position until resin hardens or rotating it back and forth.
of the foot. Attach the clip on the lateral side of the sock just below the (approx. 2 minutes).
elastic band. This will help the sock conform to the plantar arch contours. After approx. 1 hour, any
10 markings needed for lesions or
89 osseous prominences can be
made with an indelible pen. The
plastic bag can be left inside the
casting if preferred. The casts
can now be sent to the lab for
processing.1

Gently pull heel of slipper sock Have patient wiggle toes and gently slide sock off of foot, placing finger
downward and away from heel. pressure on the superior elastic band just behind base of toes.

Note: All illustrations and diagrams are of right foot 15.
1 Print FedEx labels at www.kevinorthopedic.com/fedex
2 Photos provided by STS company

3 Foot Impression Method - Clinician Process

3D Foot Scanner 1% FOOT TO IMPRESSION
VARIATION TOLERANCE
Point cloud data
ADVANTAGES
SUBMIT ORDER • Yields an accurate and precise foot model
Upload to server via software interface • Quick and clean
or email STL files and completed order • Eliminates shipping order to laboratory (digital transfer)
form to [email protected]
DISADVANTAGE
STANDARD LAB PROCESS • Accuracy during frame design process is lost due to
CAD CAM Positive Model Vacuum
Formed software and economic limitations.

FOOT MODEL DATA  CLINICAL PEARL
Stored indefinitely To achieve a balanced 3D scan, suspend foot with heel,
1st and 5th metatarsal heads in level plane while achilles
tendon is plumb-lined with Anterior Superior Iliac Spine.

3D Foot Scanner is a modern foot impression method that eliminates Elinvision and iQube Scanners
shipping impressions to the orthotic laboratory. High quality 3D Structure Sensor for iPad. Supine position acceptable
scanners collect point clouds, sets of data points in space, of patient’s iPad Scanning Interface. Supine position acceptable
feet which are converted to mesh modules through a process referred
to as surface reconstruction. Most clinical scanners can convert these TOM-CAT Scanner Interface
reconstructions in many file formats; however, the most popular are
Stereolithography files (STL). Some clinical scanning hardware and
software has encrypted mesh modules in other file formats. Kevin
Orthopedic can accept foot impressions in the format of STL files and
from various 3D clinical scanners, including but not limited to:

• Structure Sensor by Occipital
• VeriScan Podiatric Scanner (VPS)
• DelCam iQube
• TOM-CAT Foot Scanner
• Sharp Shape Foot Scanner
• Elinvision Scanner

Kevin Orthopedic offers a comprehensive selection of scanners and
applications to suit the professional clinicians needs. To learn more
visit www.kevinorthopedic.com or contact [email protected]

Note: Although most 3D scanners are capable of capturing high quality
detail in high resolution (i.e. 0.5mm for Structure Sensor), the final
orthotic frame will have a higher variation congruency than plaster or
foam impression methods with positive plaster model vacuum formed
fabrication. The cause of this variation is due to the CAD software
program’s rendering. Orthotic lab CAD technicians are economically
very limited in time to create the perfect congruent orthotic frame
matching the foot impression contour. Thus CAD software shortcuts
are used to shorten the timespan to design the file resulting in a larger
variation in shape and contour of the completed orthotic frame design.
If more time was economically feasible, a CAD technician could spend
several hours creating the CAD file. However this would significantly
increase the cost of the process.

16.

Foot Impression Method - Clinician Process 3

Pedobarography 15% FOOT TO IMPRESSION
VARIATION TOLERANCE
Pressure mat
ADVANTAGES
SUBMIT ORDER • Incorporates gait analysis
Email 1:1 scale pedobarography and completed • Quick capture
order form to [email protected] • Eliminates shipping order to laboratory

STANDARD LAB PROCESS (digital transfer)
Redimold Positive Model
DISADVANTAGES
FOOT MODEL DATA
Stored indefinitely • Does not yield an accurate and precise

Pedobarographic foot impressions are also offered as a quick foot model
capture option to produce orthotic frames. The pressure distribution
through dynamic or static pedobarographic methods provides the lab • Orthotic will have high congruency variation
technicians not only a 1:1 scale of the patient’s feet size but also an Podotech Podiatry Clinic 28/10/2010
understanding of the variety of biomechanical data, ground forces and
other kinetic motion a patient endures. The 1:1 scale reports identify Sheridan House Bridge Industrial Estate Speke Hall Road Liverpool L24 9HB. UK
metatarsal head locations, which can be offloaded as necessary, +44 (0) 151 448 1228
precise placements of other anatomical structures requiring [email protected]
modification and gait characteristics. These pressure readings, www.Podotech.com
observed arch heights and shoe sizes are used to identify redimold
positive models that would best suit the patient for fabricating TEST Age : 29 year Complaint : Area : 88 cm²
vacuum formed frames. Foot model data can be indefinitely stored, PODO Weight : 92 Kg Check-up Thrust : 24 %
and reordering additional pairs is made easier. Although the true Height : 180 cm Distribution : 52 %
contour and shape of a patient’s plantar arches are not captured, a Referral : Foot size : 44
pedobarograph is still a satisfactory method for taking a patient’s foot
impression and creating custom foot orthotics. Area : 95 cm² Static analysis
Thrust : 33 %
Kevin Orthopedic accepts 1:1 scale pedobarographic reports from any Distribution : 61 %
modern pressure mat from company, such as Tekscan and Novel.
Traditional pressure mats can also be submitted to the lab, such as Area : 57 cm² Area : 68 cm²
Harris Mat, PressureStat or Podotrack. Thrust : 21 % Thrust : 22 %
Distribution : 39 % Distribution : 48 %
Right foot results
Left foot results
Area Maximal P. Average P. Thrust
Area Maximal P. Average P. Thrust Weight Weight
50 Kg 156 cm²66.9 KPa 26.6 KPa 46 % 42 Kg
152 cm² 72.0 KPa 32.0 KPa 54 %

- Podotech Podiatry Clinic +
15/11/2010
Static analysis

Sheridan House Bridge Industrial Estate Speke Hall Road Liverpool L24 9HB. UK
+44 (0) 151 448 1228
[email protected]
www.Podotech.com

TEST Age : 30 year Complaint :
PODO Weight : 92 Kg
Height : 180 cm
Referral : Foot size : 44

Dynamic graphic : left and right foot superposition

Harris mat / Podotrack Dynamic analysis

17.

3 Foot Impression Method - Clinician Process

Existing Positive Model 1% FOOT TO IMPRESSION
VARIATION TOLERANCE
A positive foot model from previous foot orthotics
ADVANTAGES
SUBMIT ORDER • Accurate and precise foot model
Ship positive model with completed order • Can be used repeatedly for new orthotics
form to laboratory1 • Helps patient understand orthotic

STANDARD LAB PROCESS fabrication process
Vacuum Formed
DISADVANTAGE
FOOT MODEL DATA • Patient responsible for storage
Positive Model returned to clinic

Submitting an existing positive model from a patient’s Existing foot orthotic over existing
previous orthotics is another option to create custom positive model
frames and reproduce orthotics. Kevin Orthopedic
accepts positive models produced by any laboratory or
clinic. Orthotics can be produced with low congruency
variation from their pre existing models. Because
orthotics are hand finished, variances between new
and prior devices are inevitable. Pictures of the
previous devices and tracings of coverings are helpful
for lab technicians to duplicate devices as best as
possible. Despite the hand finished height and width,
the contour of the frame should have the smallest
variance of only 1%, matching with nearly perfect
congruency.

Note: For more visual images depicting positive model
vacuum formed process, please see page 20, images
8-10. To ship an existing model to the lab, print FedEx
labels at www.kevinorthopedic.com/fedex

Vacuum forming frames from existing positive
models produces near congruent accuracy of foot

contour and shape

18. 1 Print FedEx labels at www.kevinorthopedic.com/fedex

Foot Impression Method - Clinician Process 3

Redimold 0% FOOT TO IMPRESSION
VARIATION TOLERANCE 2
Shoe size & arch height
ADVANTAGE
SUBMIT ORDER • Quick and easy
Email order form to [email protected]
or submit online at www.kevinorthopedic.com DISADVANTAGE
• Device will not have a custom
STANDARD LAB PROCESS
Redimold Positive Model contoured frame shape

FOOT MODEL DATA
Stored indefinitely

Redimold is the quickest and easiest method available Arch apex of
for a clinician to acquire foot data and manufacture redimold models1
custom foot orthotics. By submitting only a shoe
size and determining if the patient has a normal, Normal 18-21mm
pes planus or pes cavus arch type, orthotics can be
produced. Planus 15-18mm

The Kevin Orthopedic lab has 11 size-based Cavus 18-24mm
prefabricated positive models for each corresponding
arch type: 33 postive models in total. The orthotic
frames are then vacuum formed over the redimolds
and nearly all custom materials, modifications and
paddings are available.

The benefits of choosing this method include fast data
acquisition, fast turnaround time for manufacturing,
and quality customized devices compared to over-
the-counter orthotics. However, there is no custom
contouring of the orthotic frame.

Always consider arch length
discrepancies to overall length.

1 Arch apex ranges overlap due to foot model size corresponding to the patient shoe size. 19.
2 0% Variation Tolerance due to no impression taken. Only shoe size and arch type required to select the consistent corresponding foot model.

3 Frame Fabrication Method - Lab Process

Plaster Positive Model Vacuum Formed 2% FRAME TO
MODEL VARIATION
Gold standard fabrication process
TOLERANCE
FOOT IMPRESSION METHODS ACCEPTED
Plaster Slipper Cast, Foam Impression, STS
Slipper Sock

FRAME MATERIAL OPTIONS 1 2
Polypropylene, Subortholene, Carbon,
TPE, EVA

ADVANTAGES
• Accurate foot model
• Allows variety of frame material options

DISADVANTAGES Plaster slipper cast and foam impression Pouring plaster into
• Physical storage 34 slipper cast
• Can break
• Irreplaceable without new positive model 5

Creating a positive model is the Kevin Unmodified plaster Confirming forefoot to Soft tissue expansion
Orthopedic standard method for producing model rearfoot balancing 7
molded frames to conform to a patient’s feet.
Whether Plaster or Foam Impression, pouring 6
plaster into a patient’s negative and creating
a positive model is the optimal method that Marking reference lines Postive plaster model on
allows the lab to observe the foot on a 1:1 8 vacuum press
scale. The preciseness of pressing a frame,
finishing the width of the orthotic, and pad 9 10
and accommodation placement is greatly
improved with a positive model because lab
technicians can see every contour, shape
and unique relationship from one anatomical
segment to the next. If precision is of the
utmost importance, the time-tested method
of pouring a positive model still provides
the best outcome. Because positive models
are heavy and occupy a lot of space, Kevin
Orthopedic will only store them for 3 months
or return the models to the clinic for patient’s
safe keeping for repeat orders.

Carbon frame before vacuum forming Vacuum forming Completed vacuum
formed process

20.

Frame Fabrication Method - Lab Process 3

CAD CAM Positive Model Vacuum Formed 10% FRAME TO
MODEL VARIATION
Computer designed and manufactured model vacuum formed
TOLERANCE
FOOT IMPRESSION METHODS ACCEPTED
Plaster Slipper Cast, Foam Impression, STS Slipper Sock,
3D Scanner

FRAME MATERIAL OPTIONS
Polypropylene, Subortholene, Carbon, TPE, EVA

ADVANTAGES Milled out CAD CAM
• Digital 3D model stored indefinitely Positive Models
• Allows variety of frame material options

DISADVANTAGE
• Some foot contour lost with routed positive model

Creating a Computer-Assisted Designed Computer-Assisted Vacuum forming
Machined (CAD CAM) positive model from an STS slipper frames over CAD
sock or 3D scan is the standard method for producing CAM Positive Models
custom-molded frames. It’s also a great option for plaster
slipper casts or foam impression if desired. The benefits of Positive Model Milling Process
using this process are indefinite digital model storage and
simplified reordering. The negative of using this method
is an increased variance in congruence accuracy. CAD
software shortcuts are used to reduce the time needed to
design the digital frame, resulting in an increased variation
between the shape and contour of the orthotic frame and the
patient’s impression model. Orthotic lab CAD technicians
are economically time limited, making it difficult to create
perfectly congruent positive model designs. Mill bit size and
mill limitations also increase the contour variation between
the patient's foot impression and the CAD CAM positive
model. Nevertheless, this is still a great method for fabricating
custom orthotics. Any calibrated frame material is available
and nearly every frame modification is available with the CAD
CAM positive model process.

Note: For more visual images depicting positive model
vacuum formed process, please see page 20, images 8-10.

Positive Model CAD (Computer-Assisted Designed) Positive Model CAD (Computer-Assisted Designed)
21.

3 Frame Fabrication Method - Lab Process

3D Printed Frame 7% FRAME TO
MODEL VARIATION
Additive manufacturing
TOLERANCE
Option not on the order form and is available as a special request
CAD file of an orthotic frame used for 3D printing or CAM.
FOOT IMPRESSION METHODS ACCEPTED Thickness of frame, tapering, smoothing and all contours
Plaster Slipper Cast, Foam Impression, STS Slipper Sock, are designed on a computer screen in this environment.
3D Scanner The superimposed positive model of the foot is used to help
the orthotic technician create the orthotic frame shape and
FRAME MATERIAL OPTIONS contour.
Nylon

ADVANTAGES
• Precise resolution in microns
• Very accurate to digital design
• No environmental waste

DISADVANTAGES
• Limited to nylon material
• CAD technician design time limitations

Kevin Orthopedic offers the option for clients to use 3D printing
through additive manufacturing for a patient’s devices. After
a patient’s foot model is digitally scanned, technicians use a
software CAD program to design a positive model and custom
frame before the Selective Laser Sintering (SLS) process, which
then produces the physical frame of the device. The benefits
of using the SLS process are that it is incredibly accurate in
producing a precise physical match to the CAD or STL digital
frame design and makes reordering easy, as the lab stores the
digital frame specifications indefinitely. The compromises of
using this method include very limited frame material options
and frame congruency limitations. Orthotic lab CAD technicians
are limited in the time they have to design orthotic frames
that are perfectly congruent with patient foot impressions.
CAD software shortcuts are used to reduce the time needed
to design the digital frame, resulting in an increased variation
between the shape and contour of the orthotic frame and the
patient’s impression model.

Close up of a SLS 3D printed orthotic. The 3D printers. 3D Printed SLS (selective laser sintering),
Layer thicknesses from Selective Laser is based on the melting of a plastic powder using a laser.
Sintering (SLS) range from 0.060mm to
0.150mm. The lower the layer thickness,
the higher the resolution and the longer
it takes to make a 3D printed object of
a given height.

22.

Frame Fabrication Method - Lab Process 3

Direct Mill Frame 18% FRAME TO
MODEL VARIATION
Subtractive manufacturing
TOLERANCE
Option not on the order form and is available as a special request

FOOT IMPRESSION METHODS ACCEPTED
Plaster Slipper Cast, Foam Impression, STS Slipper Sock, 3D Scanner

FRAME MATERIAL OPTIONS
Polypropylene, EVA

ADVANTAGES
• Consistent
• Reproducable

DISADVANTAGES
• Some contour loss
• CAD technician design time limitations

Kevin Orthopedic offers the option for clients to use direct milling CAD orthotic frame process for direct mill or 3D printing
through subtractive manufacturing for a patient’s devices. After Polypropylene Frame Milling Process
a patient’s foot model is digitally scanned, technicians take
mesurements from the patients model to design a frame before
it is submitted to the Computer Numerical Control process, which
then removes material from a block of polypropylene or EVA to
produce the physical frame of the device. The benefits of using
the CNC fabrication method are that it quickly produces frames
for multiple pairs of devices simultaneously and makes reordering
easy, as the lab stores the digital frame specifications indefinitely.
The compromises of using this fabrication method are limitations
in frame material options and frame congruency. Orthotic lab
CAD technicians are limited in the time they have to design
orthotic frames that are perfectly congruent with the patient foot
impressions. CAD software shortcuts are used to reduce the
time needed to design the digital frame, resulting in an increased
variation between the shape and contour of the orthotic frame
and the patient’s impression model.

CNC (Computer Numerical Control) Terminal Mill Bit Cutting Polypropylene Frame

23.

3 Frame Fabrication Method - Lab Process

Redimold Positive Model Vacuum Formed 2% FRAME TO
MODEL VARIATION
Predesigned models vacuum formed
TOLERANCE
FOOT IMPRESSION METHODS ACCEPTED
Redimold, Pedobarography

FRAME MATERIAL OPTIONS
Polypropylene, Subortholene, Carbon, TPE, EVA

ADVANTAGES Vacuum forming frames
• Consistent over Redimold Positive
• Quick process Models
• Positive Model Vacuum-formed
to the orthotic such as rearfoot posts, flanges, padding
DISADVANTAGE and accommodation modifications etc. The drawback of
• No custom contours this fabrication method is the lack of customized frame
contours due to a prefabricated mold being used to
If the Redimold fabrication method is preferred, Kevin vacuum form the frame instead of a patient’s impression.
Orthopedic offers a Redimold system consisting of 33
different positive models that can be vacuum formed Note: To see the full vacuum forming process, please see
with nearly any orthotic frame material. The benefits of images 8-10 on page 20.
using this system include less clinical skill needed for
casting, produces consistent orthotic frames, and ease
of ordering and reordering, as the lab stores the patient’s
order specifications indefinitely and no patient impression
needing to be submitted. Many modifications can be added

  NORMAL PLANUS CAVUS
Model Number Model Number Model Number
MEN’S WOMEN’S
SHOE SIZE SHOE SIZE 3N 3P 3C
4N 4P 4C
3 4 5N 5P 5C
4 5 6N 6P 6C
5 6 7N 7P 7C
6 7 8N 8P 8C
7 8 9N 9P 9C
8 9 10N 10P 10C
9 10 11N 11P 11C
10 11 12N 12P 12C
11 12 13N 13P 13C
12 13
13 14

24.

Fabrication Method 3

Extrinsic Post

25.

3 Optimization

Order Side

Select bilateral or unilateral for clear instruction of patient’s order.

Bilateral (Asymmetrical) Example of asymmetrical feet. Right arch is slightly higher then left arch.

Mirror Right
Mirror Left

Bilateral

If bilateral impressions are received with notable aysmmetry, the lab will
consider this asymmetry intentional and the orthotic frame will reflect
the unique contours. If a symmetrical contour is desired, due to optimal
correction captured unilaterally, or a difficult patient to cast, specifying
to mirror the desired side will result in devices with similar contour
despite variation between the impressions submitted.

Unilateral

For amputees or patients receiving a unilateral orthotic,
select the side of impression submitted.

Right Only

Left Only

26.

Optimization 3

Orthosis Fitting

The lab can fit the orthotic to a patient’s shoe gear by submitting one of the following with the order:

Tracing

When tracing an insole, undercut the heel area to properly
capture its inferior aspect, ensuring all areas that contact the
shoe board are obtained. If scanning a tracing, scan must be 1:1
scale. Tracing can be emailed to [email protected] or
shipped with the completed order form and foot impression to
laboratory.1

Note: When dispensing orthotic, be sure to check that the order
fits in the shoe properly with no buckling of the extension, and
the frame sits evenly and flatly in the shoe gear.

Insoles

An insole from the patient’s shoes can be submitted to help
precisely match the shape of the shoe with the orthotic that will
be worn. Insoles can be shipped with the completed order form
and foot impression to the laboratory.1

Note: When dispensing orthotic, be sure to check that the order
fits in the shoe properly with no buckling of the extension, and
the frame sits evenly and flatly in the shoe gear.

Shoes

For optimal fit, shoes can be submitted to the lab with an
order. This is especially helpful for hard to fit shoe gear, such
as: women’s dress shoes, riding boots, ice skates or ski boots.
Shoes can be shipped with the completed order form and foot
impression to the laboratory.1

Note: When dispensing the orthotic, be sure to check that
the device fits in the shoe properly, with no buckling of the
extension, and the frame sits evenly and flatly in the shoe gear.

1 Print FedEx labels at www.kevinorthopedic.com/fedex 27.

4 Choose Device

4

Orthotic Devices

Sixteen devices that satisfy nearly all patient
requirements. All can be modified at the clinician’s
discretion. The complete orthotic line available can be
viewed on pages 121-127 in this guide and online at
2w8w. w.kevinorthopedic.com

Orthotic Devices 4

Active

Pro Sport Custom Balance Forefoot 12mm Extrinsic Standard
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Model: A1

Active

This foot orthotic can be prescribed with: Myolite Toe Polypropylene Prolite Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Bottom Cover
Pedobarography, Positive Model Extension Frame per Weight Top Cover

Recommended For: The most universal custom foot orthosis that is effective for
• Athletic shoes with removable nearly every athletic activity.

insoles The Pro Sport is Kevin Orthopedic’s most popular, versatile and functional
• Sports injury pathologies device among active patients seeking everyday support and comfort. Designed
to fit in almost any athletic shoe with a removable insole, the Pro Sport provides
Clinical Indications: excellent support and functional correction while maintaining shock absorption
• Overpronation and cushioning for comfort. It features a polypropylene frame calibrated
• Lower extremity pathology per weight, a rigid to very rigid (55-65 Shore A) EVA extrinsic rearfoot post,
• Poor posture and a proprietary Prolite padded top cover that together, provide stability,
biomechanical control, moisture-control and cushioning. The Pro Sport is
constructed with a positive model of the patient’s foot and can be modified at
the clinician’s discretion.

Frame Filler: None

Frame Material: Polypropylene per Weight

Rearfoot Post: Extrinsic 55-65 Shore A To Toes

Heel Cup: 12mm Bottom Cover: 0.6mm Suede
Custom Congruent To Foot Model Balance Forefoot to Rearfoot

Top Cover: 2mm Prolite
Extension: 1.5mm Myolite

29.

4 Orthotic Devices Custom Balance Forefoot 12mm Intrinsic Standard
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Active

Pro EVA

Model: A7

Active

This foot orthotic can be prescribed with: EVA Frame Myolite Toe EVA Spenco Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Filler Extension Frame Top Cover Bottom Cover
Pedobarography, Positive Model

Recommended For: A flexible accommodative device with excellent shock
• Shoes with removable insoles absorption for active wear.
• Mild biomechanical control
• Strobel or board lasted shoes with The Pro EVA orthosis is an accommodative and well-padded athletic device.
The frame and arch filler are made of high-quality, durable, flexible EVA
generous width in midfoot to allow foam. By customizing the durometer of the EVA, this device can be firm and
frame filler to sit flat and level supportive, or soft and accommodating. EVA’s lightweight and shock-absorbing
properties make this a great device for athletics and vigorous activities with
Clinical Indications: repetitive impacts. The Pro EVA can be modified at the clinician’s discretion.
• Overpronation
• Lower extremity pathology
• Poor posture

Frame Material: 30 Shore A EVA Frame Filler: 30 Shore A EVA

Rearfoot Post: Intrinsic of Frame Filler To Toes

Heel Cup: 12mm Bottom Cover: 0.6mm Suede
Custom Congruent Balance Forefoot To Rearfoot
To Foot Model
Top Cover: 1.5mm Spenco
Extension: 1.5mm Myolite

30.

Orthotic Devices 4

Active

Classic Sport Custom Balance Forefoot 12mm Extrinsic
Congruent To Rearfoot Heel Cup Rearfoot Post
Model: A3

Active

This foot orthotic can be prescribed with: Standard No Polypropylene Protex
Plaster, Foam, STS, 3D Scanner, Redimold, Frame Width Extension Frame per Weight Top Cover
Pedobarography, Positive Model

Recommended For: A simple, durable, supportive device that is functionally
• Athletic shoes without effective and can fit in almost any shoe.

removable insoles The Classic Sport device has all the durability and support of the Pro Sport
• Relieving pain and but is designed for athletic-style shoes without removable insoles. It possess
a Protex top cover that terminates just proximal to the metatarsal heads and
biomechanical imbalances a rigid to very rigid (55-65 Shore A) EVA extrinsic rearfoot post. It can be
customized to have an intrinsic rearfoot post depending on the patient’s shoe
Clinical Indications: type and use. This device effectively controls overpronation and supinatory
• Overpronation movements. The Classic Sport can be modified at the clinicians’s discretion.
• Lower extremity pathology
• Poor posture

Frame Filler: None

Frame Material: Polypropylene per Weight To Mets

Rearfoot Post: Extrinsic 55-65 Shore A Bottom Cover: None
Balance Forefoot To Rearfoot
Heel Cup: 12mm
Custom Congruent Top Cover: 0.75mm Protex
To Foot Model Extension: None

31.

4 Orthotic Devices Custom Balance Forefoot 12mm Extrinsic Standard
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Active

Subo-Flex

Model: A4

Active

This foot orthotic can be prescribed with: EVA Frame Myolite Toe Subortholene Spenco Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Filler Bottom Cover
Pedobarography, Positive Model Extension Frame per Weight Top Cover

Recommended For: A semiflexible orthosis built for all day comfort, support and
• Shoes with removable insoles accommodation.
• Mild biomechanical control
• Strobel or board lasted shoes with The Subo-Flex is designed for low-impact activities, such as walking, and for patients
who spend long periods of time on their feet. It’s primarily a supportive device, but its
generous width in midfoot to allow subortholene frame provides inelastic rebound characteristics ideal for tarsometatarsal
frame filler to sit flat and level pathology. EVA frame filler provides additional stability, rigidity and shock absorption,
making this device the perfect hybrid of functional correction and cushioned support.
Clinical Indications: This device also provides substantial rearfoot control with a rigid to very rigid (55-65
• Midfoot arthritis Shore A) EVA extrinsic rearfoot post. This device has been designed to fit in most
• Midfoot joint dysfunction work and walking shoes with removable insoles. The Subo-Flex can be modified at the
• Lower extremity pathology clinicians’s discretion.
• Poor posture

Frame Filler: EVA 30 Shore A EVA

Frame Material: Subortholene per Weight

Rearfoot Post: Extrinsic 55-65 Shore A To Toes

Heel Cup: 12mm Bottom Cover: 0.6mm Suede
Balance Forefoot To Rearfoot
Custom Congruent
To Foot Model Top Cover: 1.5mm Spenco
Extension: 1.5mm Myolite

32.

Orthotic 4

Dress

Lateral Wedge
Lateral Flange

33.

4 Orthotic Devices Custom Balance Forefoot 6mm Intrinsic Narrow
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Dress

Ultra Slim

Model: L3

Dress

This foot orthotic can be prescribed with: No Carbon Frame Protex Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Extension per Weight Top Cover Bottom Cover
Pedobarography, Positive Model

Recommended For: A lightweight, supportive carbon fiber orthosis that is designed
• Dress flats and very low to fit in narrow men’s and women’s dress or fashion footwear.

volume shoes The Ultra Slim is the classic dress device designed for use in low-volume
• Control biomechanical shoes. A carbon frame keeps this orthotic model thin and lightweight while
still providing excellent support. A shallow heel cup, Protex top cover and met
pathologies length contribute to its thin design, allowing the device to fit in narrow fashion
shoes. The frame can be semi-flexible to very rigid upon request. The Ultra Slim
Clinical Indications: is constructed with a positive model of the patient’s foot and can be modified at
• Overpronation the clinician’s discretion.
• Lower extremity pathology
• Poor posture

Frame Material: Carbon per Weight Frame Filler: None

Rearfoot Post: Intrinsic of Frame To Mets

Heel Cup: 6mm Bottom Cover: 0.6mm Suede Wrap
Custom Congruent Balance Forefoot To Rearfoot
To Foot Model Top Cover: 0.75mm Protex
Extension: None

34.

Orthotic Devices 4

Dress

Cobra Custom Balance Forefoot 6mm Intrinsic Narrow
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Model: L7

Dress

This foot orthotic can be prescribed with: EVA Frame Filler No Subortholene Frame Protex Suede
Plaster, Foam, STS, 3D Scanner, Redimold, per Weight Bottom Cover
Pedobarography, Positive Model Extension per Weight Top Cover

Recommended For: An innovative orthotic solution for very narrow, low volume
• Very low volume and high shoes or high heels.

heel shoes The Cobra is an innovative solution to provide arch support in very low-volume
• High fashion shoe gear shoe styles, such as ballet flats and high heels. By drastically reducing the heel
• Midtarsal support cup into a cobra-shaped heel, this orthotic can fit in the most low-profile shoes or
• Rearfoot control heels with varying inclination angles. Because it consumes no vertical volume in
the shoe, the usual problems with heel slippage are eliminated. To prevent sliding
Clinical Indications: downward in a high heel shoe, the Cobra has a sulcus-length extension of Protex
• Overpronation and suede that allows the ball of the foot to pin the orthotic in place. The frame
• Lower extremity pathology is finished to the width of the first three metatarsals only, so it can fit into pointed
• Poor posture shoes with ease. The Cobra device is constructed with a positive model of the
patient’s foot and can be modified at the clinician’s discretion.

Frame Filler: 30 Shore A EVA

Frame Material: Subortholene per Weight

Rearfoot Post: Intrinsic of Frame Filler To Sulcus

Heel Cup: 6mm Bottom Cover: 0.6mm Suede
Balance to the Rearfoot
Custom Congruent
To Foot Model Top Cover: 0.75mm Protex
Extension: None

35.

4 Orthotic Devices Custom Balance Forefoot 6mm Intrinsic Narrow
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Dress

Subo-Flex LP

Model: L4

Dress

This foot orthotic can be prescribed with: EVA Frame Myolite Sulcus Subortholene Protex Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Filler Bottom Cover
Pedobarography, Positive Model Extension Frame per Weight Top Cover

Recommended For: A semiflexible orthosis built for all day comfort, support and
• Loafers and low volume accommodation in low volume shoes.

dress shoes The Subo-Flex LP provides the same accommodative support as the standard
• Fast relief from Subo-Flex but in a low profile version. It is ideal for active patients seeking
comfort for low-intensity activities while wearing low volume shoes. The frame
biomechanical pathologies will contour over time to fit a patient’s foot upon pronation and supination. EVA
frame filler acts as a rearfoot stabilizing post while simultaneously reinforcing
Clinical Indications: the arch, increasing shock absorption and control for a variety of pathologies.
• Midfoot arthritis Subo-Flex LP can be modified at the clinician’s discretion.
• Midfoot joint dysfunction
• Lower extremity pathology
• Poor posture

Frame Filler: 30 shore A EVA

Frame Material: Subortholene per Weight To Sulcus

Rearfoot Post: Intrinsic of Frame Filler Bottom Cover: 0.6mm Suede
Balance Forefoot To Rearfoot
Heel Cup: 6mm
Custom Congruent Top Cover: 0.75mm Protex
To Foot Model Extension: 1.5mm Myolite

36.

Orthotic Devices 4

Dress

Fashion Custom Balance Forefoot 6mm Extrinsic Standard
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Model: L1

Dress

This foot orthotic can be prescribed with: No Polypropylene Suede Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Extension Frame per Weight Top Cover Bottom Cover
Pedobarography, Positive Model

Recommended For: A soft and comfortable dress device for men and women to be
• Fashion shoes worn with or without socks.
• Sockless or nylons
The Fashion device is great for both men’s and women’s low profile shoes
Clinical Indications: without removable insoles. This device features a polypropylene frame,
• Overpronation and a 6mm heel cup. The rearfoot post provides adequate control for the
• Lower extremity pathology subtalar joint and midtarsal joints while providing minimal bulk to the device.
• Poor posture The suede top cover extends to the metatarsal heads for comfortable
wear without socks, and is finished with a suede bottom cover full wrap to
provide a soft interface in high-quality fashion shoes. The Fashion device is
constructed with a positive model of the patient’s foot and can be modified at
the clinician’s discretion.

Frame Material: Polypropylene per Weight Frame Filler: None

Rearfoot Post: Intrinsic of Frame To Mets

Heel Cup: 6mm Bottom Cover: 0.6mm Suede
Balance Forefoot To Rearfoot
Custom Congruent
To Foot Model Top Cover: .06mm Suede
Extension: None

37.

4 Orthotic Devices Custom Balance Forefoot 18-24mm Extrinsic
Congruent To Rearfoot Heel Cup 1 Rearfoot Post
UCBL

UCBL

Model: T4

UCBL

This foot orthotic can be prescribed with: Wide No Subortholene Protex
Plaster, Foam, STS, 3D Scanner, Redimold, Frame Width Extension
Pedobarography, Positive Model Frame per Weight Top Cover

Recommended For: The optimal orthosis for maximum control and stabilization, treating
• Patients requiring control across flat-foot conditions and preventing degeneration from other rigid foot
deformities.
all three planes
• Walking and athletic shoes The UCBL is the best orthotic option for patients needing maximum
stabilization. It’s the most controlling foot orthotic available and is commonly
Clinical Indications: used by adults with flexible flatfoot conditions. This device features a fully
• Postoperative encompassing heel cup with medial and lateral flanges to provide simultaneous
• Severe to moderate forefoot and control across the sagittal, coronal, and median planes. When these flanges
are combined with the custom-molded arch and an extrinsic rearfoot post, this
rearfoot pathology device stabilizes the midfoot and rearfoot, preventing any inversion, eversion,
• Hypermobile mid and rearfoot pronation, and other abnormal foot movements. The UCBL can be modified at
the clinician’s discretion.

Medium Medial Flange Frame Filler: None
Frame Material: Subortholene Frame
Rearfoot Post: Extrinsic 55-65 Shore A To Mets
Heel Cup: 18-24mm1
Custom Congruent To Foot Model Bottom Cover: None
Medium Lateral Flange Balance Forefoot To Rearfoot

Top Cover: 0.75mm Protex
Extension: None

38. 1 Heel cup depths are scalable to patient’s foot size. The larger the foot the deeper the heel cup.

Millimeter heel cup depth is a reference for size 10 men’s and size 8 women’s.

Orthotic Devices 4

UCBL

EVA UCBL Custom Balance Forefoot 18-24mm Intrinsic Wide
Congruent To Rearfoot Heel Cup1 Rearfoot Post Frame Width
Model: T9

UCBL

This foot orthotic can be prescribed with: EVA Frame No EVA Protex
Plaster, Foam, STS, 3D Scanner, Redimold, Filler Extension Frame Top Cover
Pedobarography, Positive Model

Recommended For: A unique device that maximizes control and stabilization while
• Comfortable control offering cushioning and accomodation.
• Active patients needing
The EVA UCBL is Kevin Orthopedic’s unique offering of the UCB style device
therapeutic control that is designed to provide softer ground reaction forces while still providing
• Strobel or board lasted shoes with substantial lateral and medial stabilization. This device is ideal for complicated
presentations in patients who are active and require a lightweight device that
generous width in midfoot to allow is controlling but comfortable. The EVA UCBL features an all EVA frame per
frame filler to sit flat and level weight with high, soft medial and lateral flanges and EVA frame filler to control
movement in the foot and ankle. It is covered with a durable Protex top cover
Clinical Indications: to the metatarsals. The EVA UCBL is constructed with a positive model of the
• Ankle and Midfoot Arthritis patient’s foot and can be modified at the clinician’s discretion.
• Overpronation
• PTTD Stages II, III, IV

Medium Medial Flange Frame Filler: 30 Shore A EVA
Frame Material: 30 Shore A EVA
Rearfoot Post: Intrinsic of Frame Filler To Mets
Heel Cup: 18-24mm1
Custom Congruent To Foot Model Bottom Cover: None
Medium Lateral Flange Balance Forefoot To Rearfoot

Top Cover: 0.75mm Protex
Extension: None

1 Heel cup depths are scalable to patient’s foot size. The larger the foot the deeper the heel cup. 39.
Millimeter heel cup depth is a reference for size 10 men’s and size 8 women’s.

4 Orthotic Devices Custom Balance Forefoot 16mm Extrinsic
Congruent To Rearfoot Heel Cup Rearfoot Post
UCBL

Pediatric UCBL

Model: T6

UCBL

This foot orthotic can be prescribed with: Standard No Subortholene Protex
Plaster, Foam, STS, 3D Scanner, Redimold, Frame Width Extension
Pedobarography, Positive Model Frame per Weight Top Cover

Recommended For: A pediatric version of the UCBL that provides maximum support
• Children ages 3-16 and control that can result in positive permanent changes in
• Patients with reducible deformity foot architecture.

and pathology The Pediatric UCBL is designed for children ages 3-16 with reducible foot
• Sport specific shoes deformities as well as those who would benefit from having a device to provide
biomechanical control across all 3 planes of movement. Similar to the standard
Clinical Indications: UCBL device, this pediatric version provides rigid support via high flanges and
• Severe to moderate forefoot and a less deep heel cup. Because of the slightly less deep heel cup1, it is built with
children’s athletic shoes and activity in mind. In many cases, the change in foot
rearfoot pathology architecture instigated by the device is maintained even after the device is
• Hypermobile mid and rearfoot no longer used or needed. The Pediatric UCBL is constructed with a positive
• Toe walking model of the patient’s foot and can be modified at the clinician’s discretion.
• Outoeing
Frame Filler: None
High Medial Flange

Frame Material: Subortholene per Weight To Mets
Rearfoot Post: Extrinsic 65-75 Shore A

Heel Cup: 16mm Bottom Cover: None
Custom Congruent To Foot Model Balance Forefoot To Rearfoot
High Lateral Flange
Top Cover: 0.75mm Protex
Extension: None

40. 1 Heel cup depths are scalable to patient’s foot size. The larger the foot the deeper the heel cup.

Millimeter heel cup depth is a reference for size 10 men’s and size 8 women’s.

Orthotic Devices 4

UCBL

Modified UCBL Custom Balance Forefoot 12mm Extrinsic Wide
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Model: T5

UCBL

This foot orthotic can be prescribed with: Myolite Toe Subortholene Protex Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Bottom Cover
Pedobarography, Positive Model Extension Frame per Weight Top Cover

Recommended For: A versatile variation of the UCBL optimal in treating flat-
• Patients requiring moderate foot conditions or prevent degeneration of other rigid foot
deformities.
control across all three planes
• Walking and athletic shoes with The Modified UCBL is designed to be a more versatile variation of the classic UCBL
device. With a lower heel cup, a full-length padded extension and a polypropylene
removable insoles frame, this device is a great option for patients requiring a device with high control in
active applications. Its progressive design is ideal for controlling moderate to severe
Clinical Indications: overpronation as well as other biomechanical pathologies. This device includes a high
• Postoperative lateral and medial flange, but without the encompassing and restrictive heel cup. This
• Moderate forefoot and rearfoot provides the patient with moderate control across all three planes while still being
compatible with a wide assortment of shoe types. The Modified UCBL is constructed with
pathology a positive model of the patient’s foot and can be modified at the clinician’s discretion.
• Hypermobile mid and rearfoot

Low Medial Flange Frame Filler: None
Frame Material: Subortholene per Weight
Rearfoot Post: Extrinsic 65-75 Shore EVA To Toes
Heel Cup: 12mm
Custom Congruent To Foot Model Bottom Cover: 0.6mm Suede
Low Lateral Flange Balance Forefoot To Rearfoot

Top Cover: 0.75mm Protex
Extension: 3mm Myolite

41.

4 Orthotic Devices Custom Balance Forefoot 12mm Extrinsic Wide
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Therapeutic

Care Firm

Model: T2

Therapeutic

This foot orthotic can be prescribed with: Myolite Toe Polypropylene Plastazote & Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Extension Frame per Weight Glove Leather Bottom Cover
Pedobarography, Positive Model
Top Cover

Recommended For: A supportive device with accommodative covering that provides
• Active Geriatric Patients everyday control and comfort for active geriatric patients.
• Walking and athletic shoes with
The Care Firm is ideal for active geriatric patients requiring more substantial rearfoot
removable insoles control than what is provided by purely accommodative devices. This orthotic is
covered with glove leather and Plastazote to accommodate and reduce friction
Clinical Indications: against the skin’s surface, but its rigid polypropylene frame provides a higher degree
• Poor biomechanical alignment of biomechanical control. This control provided by the 4mm frame assists the patient
• Arthritis of rearfoot or forefoot in maintaining balance and stability. A firm extrinsic rearfoot post provides varus or
• Plantar fibromas valgus subtalar joint control. The Care Firm is constructed with a positive model of the
• Exostosis prominences and patient’s foot and can be modified at the clinician’s discretion.
Note: For less active patients, the more accommodative Care Soft device may be more
deformities suitable.
• Ganglion cysts
• Ledderhose or plantar fibromatosis

Frame Filler: None

Frame Material: Polyproylene per Weight

Rearfoot Post: Extrinsic 65-75 Shore EVA To Toes

Heel Cup: 12mm Bottom Cover: 0.6mm Suede

Custom Congruent Balance Forefoot To Rearfoot
To Foot Model Top Cover: 3mm Plastazote
and 1mm Glove Leather
Extension: 1.5mm Myolite

42.

Orthotic Devices 4

Therapeutic

Care Soft Custom Balance Forefoot 12mm Intrinsic Wide
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width
Model: T1

Therapeutic

This foot orthotic can be prescribed with: EVA Frame Myolite Toe Cork EVA Plastazote & Suede
Plaster, Foam, STS, 3D Scanner, Redimold, Filler Extension Frame Glove Leather Bottom Cover
Pedobarography, Positive Model
Top Cover

Recommended For: A supple and accommodative device that is customizable to
• Active to sedative patients offload bony prominences.
• Walking and athletic shoes with
The Care Soft is an accommodative device ideally suited for geriatric patients
removable insoles who are not highly active. Designed for walking shoes with removable insoles,
this device has a specialized cork EVA frame reinforced with EVA arch fill,
Clinical Indications: providing shock absorption and comfort. This device is covered with high-
• Arthritis of rearfoot or forefoot quality Plastazote and glove leather top covers, which mold to the foot and
• Exostosis prominences and reduce friction against the skin’s surface. A suede bottom cover extends from
the heel to the toes to prevent slippage and protect the frame filler. The Care
deformities Soft can be modified at the clinician’s discretion.
• Ganglion cysts Note: For patients requiring more control, the Care Firm device is
• Ledderhose or plantar fibromatosis recommended.
• Hypersensitive feet
• Plantar fibromas

Frame Filler: 30 Shore A EVA

Frame Material: 3mm Cork EVA Frame To Toes
Rearfoot Post: Intrinsic of Frame Filler

Heel Cup: 12mm Bottom Cover: 0.6mm Suede
Balance Forefoot To Rearfoot
Custom Congruent
To Foot Model Top Cover: 3mm Plastazote
and 1mm Glove Leather

Extension: 1.5mm Myolite

43.

4 Orthotic Devices

Therapeutic

Therapeutic Custom Balance Forefoot 12mm Intrinsic Wide
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width

EVA Frame No EVA Plastazote
Filler Extension Frame Top Cover

Recommended For: Essential devices for the Medicare Therapeutic Shoe Program
• Diabetes Mellitus
• Diabetic therapeutic shoe program Diabetic inserts are recommended if the patient suffers from diabetes,
has a certified physician managing the patient’s systemic disease under
Clinical Indications: a comprehensive plan for diabetes and possesses one of the following: a
• Exostosis prominences and previous amputation of the other foot (partial or entire), history of previous
foot ulceration of either foot, history of pre-ulcerative calluses of either foot,
deformities peripheral neuropathy with evidence of callus formation on either foot,
• Ulcers deformity of either foot, or poor circulation in either foot.
• Poor circulation
• Pre-ulcerative calluses

Frame Filler: 35 Shore A EVA

Frame Material: 35 Shore A EVA To Toes

Rearfoot Post: Intrinsic of Frame Filler Bottom Cover: None
Balance Forefoot To Rearfoot
Heel Cup: 12mm
Custom Congruent Top Cover: 3mm Plastazote
To Foot Model Extension: None

Three Pairs
Two Pairs
One Pair

44.

Orthotic Devices 4

Therapeutic

Premium Diabetic

Model: T3

Therapeutic Custom Balance Forefoot 16mm Intrinsic Wide
Congruent To Rearfoot Heel Cup Rearfoot Post Frame Width

This foot orthotic can be prescribed with: EVA Frame Myolite Toe EVA Plastazote
Plaster, Foam, STS, 3D Scanner, Redimold, Filler Extension Frame Top Cover
Pedobarography, Positive Model

Recommended For: A high quality and accommodative device with a special top
• At risk diabetic patients cover for at-risk diabetic patients.
• Extra depth shoes with
The Premium Diabetic is ideal for diabetic, at-risk patients who need quality
removable insoles diabetic insoles that are far superior to that of standard diabetic inserts. These
• Strobel or board lasted shoes custom-molded foot orthotics have been proven to reduce pressures causative
of ulcers in patients with decreased circulation and sensitivity. Its accommodative,
with generous width in midfoot custom molded design features an EVA frame that extends to the sulcus and a
to allow frame filler to sit flat thick Plastazote full length top cover that immediately molds to the patient’s foot
and level helping to minimize friction. This orthotic is finished wide to support the entire
plantar surface of the foot, so it is recommended for use with extra depth shoes or
Clinical Indications: shoes with removable insoles. The Premium Diabetic is constructed with a positive
• Diabetes Mellitus model of the patient’s foot and can be modified at the clinician’s discretion.
• Hypersensitive feet
Frame Filler: 30 Shore A EVA
Frame Material: 30 Shore A EVA

Rearfoot Post: Intrinsic of Frame Filler To Toes

Heel Cup: 16mm Bottom Cover: None
Balance Forefoot To Rearfoot
Custom Congruent
To Foot Model Top Cover: 3mm Plastazote
Extension: 1.5mm Myolite

45.

A Materials

A

Materials

Covering and frame material options improve clinical
management of biomechanical compression and
shear loads for each unique individual.

46.

Materials A

Top Cover / Bottom Cover / Frame

 MATERIALS A OPTIONAL

Length of Cover: To Mets To Sulcus To Toes FRAME Flexible Semi Semi Rigid Very Most
Flexible Rigid Rigid Rigid
5 6
TOP Prolite  2  3 (mm) Spenco  1.5  3 (mm) Protex  0.75 (mm) PolyPro mm N/A 2  3  4  N/A N/A
COVER Glove Leather  1 (mm) Suede  0.6 (mm) Plastazote  0.75 (mm)
Subo mm N/A 2  3  4  3  3 TL 
BOTTOM N/A N/A
COVER  Glue only heel of top cover for placing forefoot pads in clinic Carbon mm N/A 1.5  2  2.5  N/A N/A

Suede  0.6 (mm) Suede Bottom Wrap  0.6 (mm) TPE mm 3  4  N/A N/A
Protex  0.75 (mm) Myolite  1.5  3 (mm)
EVA Shore A 15  30  45  65 

Top Cover pg 48-53 To Mets To Sulcus To Toes

Top coverings are the most superior placed material on the
orthotic, covers all components of the orthotic and interfaces with
the patient’s foot.

Length of Top Cover To Mets
To Sulcus
Length of cover instruction will supersede all other modification To Toes
instructions including extensions and paddings.
Frame is the most important component
A met length top covering originates at the heel and terminates for orthotic and foot function
proximal to metatarsal heads. Metatarsal length covers allow
maximum room for metatarsal heads and toes in shoe gear.

A sulcus length top covering originates at the heel and
terminates distal to the metatarsal heads, at the foot’s sulcus.
Sulcus length covers are great for modifications and postings that
treat forefoot pathologies while leaving space for the toes.

A toe length top covering originates at the heel and terminates
distal to the toes approximately 12mm distal from each phalange.
Ideal for shoes with removable insoles and toe comfort. Often
coverings to toes will need to be trimmed to fit to shoe gear.

Bottom Cover pg 54-57

Bottom coverings are the most inferior placed material on the
orthotic. It provides protection from shearing forces between the
shoe and orthotic.

Frame pg 58-63

In most orthotics, the frame is the most important component. A
frame’s function is to support the aligned foot structures that were
created during the foot impression. It is the core of the orthotic
in which all postings, accommodations, paddings and cushions
are added. The congruency of the frame to the foot maximizes
effectiveness of orthotic reactionary forces.

Note: All illustrations and diagrams are of right foot 47.

A Materials  2  3 (mm)

Top Cover Black
Blue
Perforated cushioned polyethylene foam Red

FEATURES: 3mm
• Lightweight
• Compression resistant cushion
• Perspiration management design
• Superior durability
• Favorable compression set ratio for athletic applications

CLINICAL INDICATIONS:
• Active patients

Prolite is a closed-cell polyethylene foam top
cover material that sits on the superior surface
of the orthotic, covering the entire heel cup and
extending to a desired length: mets, sulcus or
toes. It is available in 2mm and 3mm thicknesses.
Prolite is perforated and has a density of 35
Shore A durometer (medium soft) that provides
perspiration management, compression resistance
and a lightweight, durable design. Because of
Prolite’s attributes, it is used widely for active
patients or athletic applications and may not be
suited for patients with sensitive feet. As a top
covering, Prolite covers any modifications or
additional materials requested and comes into
direct contact with a patient’s plantar foot.

Lateral view 2mm

Available lengths:

To Mets To Sulcus To Toes

48. Superior view

Note: All illustrations and diagrams are of right foot

Materials A

Top Cover

Neoprene foam covered with  1.5  3 (mm)
multi-stretch nylon fabric
Black
FEATURES:
• Resilient cushioning 3mm
• Low friction top cover
• Resistant to decay and odor
• Prevents blisters
• Absorbs vertical forces
• Absorbs lateral shear

CLINICAL INDICATIONS:
• Sedentary to active patients

Spenco is a two-layered top cover material
consisted of nylon and neoprene that sits on
the superior surface of the orthotic, covering
the entire heel cup and extending to a desired
length: mets, sulcus or toes. Spenco’s nylon, a
thermoplastic material that resembles silk, and
neoprene, a synthetic rubber that has similar
consistencies with wetsuit material, together
provide incredible flexibility, comfort, shock
absorption and temperature range. However,
because this material tends to absorb and
distribute perspiration, it will stay wet slightly
longer than other materials. Spenco is also
slightly heavier and over time its nylon with
delaminate with extended use. As a top
covering, Spenco covers any modifications or
additional materials requested and does come
into direct contact with a patient’s plantar foot.

Lateral view 1.5mm

Available lengths:

To Mets To Sulcus To Toes

Superior view

Note: All illustrations and diagrams are of right foot 49.

A Materials  0.75 (mm)

Top Cover Black

Performance synthetic leather Lateral view 0.75mm

FEATURES: Superior view
• Durable
• Anti-odor
• Antibacterial
• Thin
• Water resistant
• Non-animal product

CLINICAL INDICATION:
• Dress devices

Protex is a thin, synthetic leather top cover material that
sits on the superior surface of the orthotic, covering the
entire heel cup and extending to a desired length: mets,
sulcus or toes. It is commonly selected for dress devices
because of its attractive glossy black appearance,
its minimal thickness and weight, and resistance to
harboring bacteria and odor. Protex tends to be more
stiff and more water resistant than glove leather;
however, it is not recommended for high levels of
activity because of its lack of padding. As a top covering,
Protex covers any modifications or additional materials
requested and comes into direct contact with a patient’s
plantar foot.
Note: Pairing Protex with a cushioned layer (e.g. Myolite)
will provide more comfort if desired.

Available lengths:

To Mets To Sulcus To Toes

50. Note: All illustrations and diagrams are of right foot