Abstract: The system (7) for plotting the shape of a tri-dimensional object (2) is used in particular for the profile of a plantar arch (20). It comprises a sensing device (1) having rods (3) movable in a support (10, 11) such that said object (2) can be applied onto the first end (300) of each of said rods under a determined pressure force so as to drive said rods (3) in a translation motion and such that the set of the second ends (301) of said rods (3) define a surface (S.sub.A) replicating said shape to be plotted (20). Spring means (4) are associated with said movable rods (3) to oppose a calibrated resilient force opposing said pressure force. The system further comprises a contactless acquisition device (5) for acquiring and digitalizing said surface (S.sub.A) replicating said shape to be plotted (20), said device (5) delivering output electric signals (V.sub.S) correlated with the space coordinates of said second end (301) of said rods (3), with respect to reference coordinates (P.sub.

Abstract: A method and apparatus for preparing an orthotic appliance to correct defects in a foot providing the steps of scanning a foot, creating a three-dimensional model of the corrected foot, milling a positive mold of the corrected foot, forming a uniformly thick orthotic material over the positive mold and milling out the bottom of the orthotic appliance. Also provided is a heel bisector for use in preparing an orthotic appliance.

Abstract: A method for making a customized orthotic device utilizing a pre-made sole having a plurality of elongated members extending from the bottom of the sole and inserting each of the elongated members into apertures of a cutting device. Once inserted through the apertures, the distal tips of the elongated members contact a resistance layer which resists the downward movement of the elongated members. A person's foot is then rested on the topside surface of the insert; thereby depressing the insert and elongated member tips into the resistance layer. The compressive force of the foot against the resistance layer tends to conform the insert about the plantar aspect of the foot. A cutting mechanism is then used to cut the elongated members. The finished product, is customized to the foot of the person and is ready to be inserted into a shoe.

Abstract: A custom-made shoe of a sandal-type having a sole, an orthotic unit prescribed specially for the foot of the wearer adhered to the sole a vamp unit secured forwardly to the sole, and a counter secured to and projecting upwardly from the rear periphery of the sole.

Abstract: The present invention relates to bio mechanical corrective devices, commonly known as orthotics, which are used to support the foot and to correct musculo-skeletal misalignments. A method of manufacture of an improved orthotic and an orthotic made by the method are disclosed.

Abstract: The present invention relates to a footwear insole with an integral sock lining embedded therein; and to a method of making a sample comprising: preparing a board of a material selected from the group of porous and foamed cross-linked synthetic polymers; preheating the board to at least the softening point of said material; pressing the board and stamping into it a footprint shaped cavity while cooling by a stamping device having a stamping die and a stamping die bearing pressing plate; attaching a sock lining to said footprint shaped cavity; and suitably cutting the board. The sock lining may be fastened to the stamping die bearing pressing plate. Alternatively, said plate may carry an integral stamping die and the sock lining inserted after storing.

Abstract: A foot impression unit is provided with an array of gauging elements, a control mechanism for urging the gauging elements into contact with the undersurface of a person's foot to form an impression of the undersurface of the foot, a locking mechanism for releasably locking the gauging elements in place to retain that impression, and a sensing mechanism for scanning the gauging elements to produce digital signals indicative of the positions of the gauging elements. These digital signals are stored and processed by a computer to provide a stored data record serving as a digital representation of the impression of the undersurface of the foot. The computer may also be employed to provide stored additional information for modifying that data record to compensate for a perceived defect of the foot.

Abstract: A method of producing a custom-fitting article such as a custom-fitting footbed (for example, a removable insole), a custom-fitting hand grip, a custom-fitting body pad, and a custom-fitting orthopedic cast. A member for producing same and a composition for use in connection therewith are also provided. A member, such as a gel pad or gel-filled envelope, is provided which comprises a body of formable material having a minimum setting temperature greater than 130.degree. F. and being setable by heating for a period not exceeding 30 minutes and subsequent cooling. The member is conformed by biasing it against a body part of a person or mammal with sufficient pressure to conform the member to the shape of the body part. The member is then heated for a period not exceeding 30 minutes and thereafter cooled so that the formable material is set and the member remains flexible while resiliently retaining an impression of the body part.

Abstract: Polymer matrix composite materials containing a thermoplastic composite core bonded integrally with a fabric layer are provided. The fabric layer has a greater elasticity than the core, so that the fabric layer can conform smoothly to the core during thermoforming. This improvement has been demonstrated to improve aesthetic appearance and nearly eliminate wrinkling and distortion of the fabric layer when compared to conventional composite materials.

Abstract: Orthopedic splint materials made with thermoplastic polyester, particularly poly (epsilon-caprolactone) with a molecular weight of over 5,000 and melting between 50.degree. C. and 100.degree. C. have improved properties when subjected to gamma radiation in the range from 0.5 to 30 megarads.

Abstract: An insert forming apparatus and method is provided for making an insert to conformingly fit a shoe and a person's foot within the shoe. The method for practicing the invention includes using standard molding techniques to form a mold of the bottom of the last and using the mold to vacuum form a lower shell half that conforms to the bottom of the last. With the lower shell half covering the mold and having vacuum communicating holes drilled therein, the last is placed in the lower shell half and the upper shell half is drawn down over the last and lower shell half by vacuum forming. When the upper and lower shell halves have been formed, a hole is drilled in the lower shell half for injecting curable material. A sheet of fabric or leather is placed over the lover shell half, a person's foot is placed on the fabric or leather in the lower shell half, and the upper shell half is placed over the person's foot and fastened to the lower shell half.

Abstract: Systems and methods are provided for measuring bottom facing surfaces of a foot which comprise placing the foot against a reference surface, projecting light against the foot, and displaying an image of the foot on a visual display to differentiate relative distances of portions of the foot from the reference surface. In addition, the image differentiates portions of the foot exerting different pressures against the reference surface.

Abstract: A kit for use in preparing a last, i.e., an anatomical model of the human foot for use in the contruction of custom footwear, as well as a method of preparing lasts, the lasts prepared by such a method, and the custom footwear constructed by the use of such lasts. The kit includes a hardenable, shell-forming fabric that can be conformed to the shape of the foot, hardened in its conformed shape, and removed from the foot in a manner that does not substantially destroy its conformed shape. The resultant shell, being sufficiently smooth and being of substantially the same size and shape as the foot, can be used directly as a positive model of the foot.

Abstract: A conformable device (20) containing a conformable material (41) substantially comprising fluid matter which forms a resilient material substantially comprising solid matter after a working time is used in an article of footwear (44) in order to enhance conformance, comfort, fit, stability, cushioning and shock-absorption. The conformable material (41) is contained within a chamber (51) of suitable configurations. In addition, a foam material (66) of select shape generally conforming to a portion of the wearer's anatomy can be used in cooperation with the conformable material (41), as well as a void (40) containing a gas. The invention permits accommodation to a wide range of anatomical features and characteristics found amongst a large percentage of the general public and application within numerous types of footwear (44).

Abstract: A method and apparatus for producing an insole for a foot including defining a flexible insole housing in which is disposed a deformable material impregnated with an uncured resin, activating the resin for initiating curing thereof, locating the foot on the insole housing and allowing the resin to harden and thus, to preserve the configuration defined by the bottom of the foot.

Abstract: A method for the production of inserts or the like is shown, with a patient or also a healthy person standing/walking/sitting/lying/biting in a defined position and/or movement with the body part to be fitted (foot, buttocks/back, teeth) on/over an electronic measuring arrangement for two- or three-dimensional measurement of the forces (pressures) acting on the measuring arrangement. The output signals of the measuring arrangement corresponding to the pressure-force distribution under the body part in the two- or three-dimensional pattern of the pressure-force distribution are relayed to a computer and compared with a stored set of desired values (wanted or ideal data).

Abstract: An orthotic, for providing proper support for a patient's foot within a shoe has provided on its top and bottom surfaces closely spaced substantially parallel grooves. The grooves on the top surface control slippage of the foot across the orthotic while the grooves on the bottom surface of the orthotic control slippage of the orthotic relative to the shoe's insole. The orthotic is shaped from a single monolithic workpiece by guiding a computer-controlled milling tool along substantially closely spaced parallel passes in a preselected pattern across the workpiece to thereby produce the orthotic's surface contours and surface texture in a single operation.

Abstract: A method and apparatus are provided for relatively convenient and efficient production of custom molded inserts for shoes. The apparatus utilizes a molding pillow arrangement, upon which a user stands during use. The molding pillow arrangement has a composite construction including a first resilient layer, a middle resilient layer and a bottom support layer. The bottom support layer preferably includes a generic arch curve therein. The upper resilient layer is formed from a relatively soft foam, and thus molds around a user's feet. The middle layer is resilient, but relatively hard by comparison to the upper layer. The middle layer provides for a relatively firm cushion underneath the user's foot, facilitating contouring of a molded insert to the bottom of the user's foot. Preferably, at least the upper cushion portion of the molding pillow arrangement comprises left and right cushions, independently moldable with respect to a user's left and right feet.

Abstract: The invention is concerned with an orthotic fitting device and method. An envelope and an adjacent diverticulum are connected to one another and are filled with a known amount of a viscous fluid. The diverticulum has indicia on it capable of indicating what portion of the fluid is within the diverticulum. The envelope is fitted against a portion of a patient's body which is to be cushioned and the fluid adjusts between the envelope and the diverticulum to provide proper cushioning for the foot. Flow communication is stopped between the diverticulum and the envelope and the amount of fluid in the diverticulum is determined from the indicia. An orthotic device in the shape of the envelope is then formulated containing the amount of fluid which remained in the envelope of the fitting device.

Abstract: A custom insole is made up of a plurality of layers of a thermoformable material united together at their interfaces to conform in size and contour to the bottom surface of a foot, the layers comprising at least one strength layer and at least one filler layer united to the strength layer and contoured to conform to the bottom surface of the foot; and an arch flange curves upwardly for a distance to laterally support the bone structure in the arch area of the foot. In the method of making the insole, an unformed blank of thermoformable material is placed on a resilient support portion with the ball portion on a firm surface and, by placing the foot on top of the layers and applying downward pressure, it will cause the heel of the foot to form a depression in the heel portion and the ball portion of the foot to flatten out the layers resting on the firm surface.

Abstract: A custom insole is made up of a plurality of layers of a thermoformable material united together at their interfaces to conform in size and contour to the bottom surface of a foot, the layers comprising at least one strength layer and at least one filler layer united to the strength layer and contoured to conform to the bottom surface of the foot; and an arch flange curves upwardly for a distance to laterally support the bone structure in the arch area of the foot. In the method of making the insole, an unformed blank of thermoformable material is placed on a resilient support portion with the ball portion on a firm surface and, by placing the foot on top of the layers and applying downward pressure, it will cause the heel of the foot to form a depression in the heel portion and the ball portion of the foot to flatten out the layers resting on the firm surface.

Abstract: A method and apparatus are provided for relatively convenient and efficient production of custom molded inserts for shoes. The apparatus utilizes a molding pillow arrangement, upon which a user stands during use. The molding pillow arrangement has a composite construction including a first resilient layer, a middle resilient layer and a bottom support layer. The bottom support layer preferably includes a generic arch curve therein. The upper resilient layer is formed from a relatively soft foam, and thus molds around a user's feet. The middle layer is resilient, but relatively hard by comparison to the upper layer. The middle layer provides for a relatively firm cushion underneath the user's foot, facilitating contouring of a molded insert to the bottom of the user's foot. Preferably, at least the upper cushion portion of the molding pillow arrangement comprises left and right cushions, independently moldable with respect to a user's left and right feet.

Abstract: A foot impression unit is provided with an array of gauging elements, a control mechanism for urging the gauging elements into contact with the undersurface of a person's foot to form an impression of the undersurface of the foot, a locking mechanism for releasably locking the gauging elements in place to retain that impression, and a sensing mechanism for scanning the gauging elements to produce digital signals indicative of the positions of the gauging elements. These digital signals are stored and processed by a computer to provide a stored data record serving as a digital representation of the impression of the undersurface of the foot. The computer may also be employed to provide stored additional information for modifying that data record to compensate for a perceived defect of the foot.

Abstract: An article of footwear contoured to the foot of a wearer is constructed by first making a rough sole element. The element is made by taking a negative impression of a wearer's foot while in a non-weight bearing neutral biomechanical alignment. The edges and undersurface of the rough sole element are then contoured to form a finished sole which acts to maintain the neutral biomechanical alignment while in use.

Abstract: A disposable hygienic shoe insole comprises three layers; a top layer of a spunbonded polypropylene material, a composite layer of pulp fibers and polypropylene fibers meltblown onto the top layer, and a bottom layer of polyethylene vinyl acetate meltblown onto the composite layer. The layers, preferably the composite layer, can include antimicrobial agents, fragrance, or neutralizer or odor-absorbing agents. The top surface of the top layer is provided with good abrasion resistance, and the bottom surface of the bottom layer provides required friction to maintain the shoe insole in place during use.

Abstract: A contour molded insole for footwear and method for producing the same to conform to an individual's foot includes at least one layer of material which is provided with plasticity for permitting shaping of the insole. An insole blank is shaped to include an upwardly concave surface portion which, under pressure, is caused to invert to form a convex surface. The insole is provided with a heelbone relief portion and layers of textile and cushioning material for completing a preferred embodiment.

Abstract: A hybrid composite material is constructed from woven reinforced fabrics of Kevlar 49 and biaxially reinforced fibers of graphite and E-Glass bonded together with a thermosetting adhesive, for the application of custom orthotics. The material is designed with the idea of introducing different fibers at different locations of the orthotic in order to take advantage of the unique properties of each reinforcing fibers. The resulting material creates a hybrid composite that exhibits a balance of properties, in both the longitudinal and transverse directions, unavailable with any single reinforcing fibers. A method of orthotic manufacturing involves a hand lay-up and forming procedure. The constructed composite material is formed and pressed on a prescribed cast, then allowed to cure under pressure. The post-cured material is stripped from the cast, then cut and ground and finally finished to the required orthotic.

Abstract: A relatively rigid cap is made of a material which is deformable at moderately elevated temperatures. A flexible blank contoured to fit a person's foot is placed against the cap which is at the elevated temperature, and these two are placed against the plantar surface of the foot. A plastic bag is placed around the cap, the blank and the foot, and a blank is applied to conform the cap and the blank to the person's foot so as to make a custom fit orthotic. Upon cooling, the cap remains properly contoured relative to the plantar surface of the foot.

Abstract: A custom molded insole for supporting the human foot in a ski boot or other footwear is disclosed. The insole is a one-piece, thin, contoured blank of semi-rigid, bendable, resilient material molded to include the complete detail of the full plantar surface of a foot. The insole provides a four-point contact with a supporting surface or ski boot at the heel, great toe, and at least two spaced metatarsal heads to provide natural balance and proper dynamic positioning of the foot and immediate energy transfer between the foot and various footwear such as a boot/ski when skiing.Also disclosed is the method for making the custom insole including forming a negative impression of the plantar surface in an impression retaining material by pressing the foot into the material while bearing at least a portion of the body weight on that foot with the impression material firmly supported on a rigid surface.

Abstract: A custom molded insole for supporting the human foot in a ski boot or other footwear is disclosed. The insole is a one-piece, thin, contoured blank of semi-rigid, bendable, resilient material molded to include the complete detail of the full plantar surface of a foot. The insole provides a four-point contact with a supporting surface or ski boot at the heel, great toe, and at least two spaced metatarsal heads to provide natural balance and proper dynamic positioning of the foot and immediate energy transfer between the foot and various footwear such as a boot/ski when skiing.Also disclosed is the method for making the custom insole including forming a negative impression of the plantar surface in an impression retaining material by pressing the foot into the material while bearing at least a portion of the body weight on that foot with the impression material firmly supported on a rigid surface.

Abstract: A canting adjustment for ski boots and a method of canting in which the ski boot contains a plurality of wedge shaped removable innersoles having generally equal and opposite wedge angles to allow a wide range of canting angles.

Abstract: A method of fitting ski boots to a skier by standing the skier in the boots on orthotics with the skier's feet ankles and legs unconfined by the boots, recording the relative lateral locations of the skier's knees and boots, repeating the process with the skier's feet supported on the orthotics and confined by the boots, and adjusting the boots to provide the same relative lateral locations of knee and boot.

Abstract: A shoe or sandal is chosen which fits the patient's foot. One or more blanks of thermosoftening expanded plastics (e.g. an expanded cross-linked polyethylene) for constituting the insole are heated above the softening temperature and inserted in the shoe. The shoe is fitted on the patient's foot and the patient is walked until the insole is below the softening temperature. The insole may remain in the shoe or may be transferred to the patient's own footwear.

Abstract: A biplanar posting device having a board with a rear edge and a front edge and lines passing from the rear edge toward the front edge diverging toward the front edge and intersecting the front edge at an angle of about 70 degrees with a plate fixed to the upper surface of the board having end planar portions held in contact with the board and central diverging portions in the form of two flat planes diverging from the upper surface of the board at about 4 degrees and intersecting the planes in contact with the board at a line that overlays the diverging lines. An orthotic properly placed on the device and packed with plastic beneath the heel portion will inherently be formed with a lower surface to correct a defect in the bones of a patient.

Abstract: A footbed support for footwear comprises a laminate footbed custom formed to the shape of the wearer's foot from laminae of water-activated, polyurethane-impregnated fabric sheet material. The footbed is formed by placing the water-activated lamina on a resilient domed foot pad, then placing the foot in a predetermined position on the pad over the laminae so that the longitudinal arch of the foot overlies a portion of the dome corresponding to the height of the longitudinal arch and shape of the sole of the foot. The foot is then weighted to form an impression in the laminate, and the laminate allowed to partially cure before the foot is removed. Before final placement of the foot on the pad, the laminae are cut to differential lengths and widths if desired to provide a desired differential flexibility, rigidity, and thickness in different areas of the cured laminate footbed.