Abstract: In at least some embodiments, an orthotic footbed assembly includes a three-dimensional footbed that closely approximates a size and configuration of a particular foot and at least one orthotic feature additively coupled to the three-dimensional footbed. In at least some other embodiments, a method of making the orthotic footbed assembly includes direct printing of orthotic features onto a 3-D footbed. Another method includes indirect printing of orthotic features and applying these features onto to a 3-D footbed. And yet another method includes direct printing of orthotic features onto a 2-D blank footbed and then conducting a three-dimensional forming operation to make the orthotic footbed assembly.

Abstract: An insole assembly for a shoe or other article of footwear. The assembly includes a soft, cushioning foam blank having an upper surface which is contoured to engage the plantar surface of a foot, and a thin, substantially rigid, resiliently flexible cap which is mounted to the bottom of the blank so as to extend around the heel end and forwardly along the medial and lateral sides thereof. The rigid cap includes an upstanding wall which engages and buttresses the perimeter of the foam blank, and a series of medial and lateral flanges which extend across and support the bottom of the blank. The flanges are configured to cooperate with the foam blank to define zones of support in specific areas, with the maximum support and rigidity being provided for the rearfoot and midfoot areas of the foot.