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 foot support is prepared based upon a scan of the foot. The foot support has radial ridges and grooves on its upper and lower sections. The ridges and grooves converge at an imaginary center outside the foot print. The surface contour of the support do not duplicate the topography of the foot, but perform prescription manipulations.

Abstract: A new method of making custom fitted products and products made by such a method for improving the fit and comfort of such products. The invention includes incorporating a hollow, sealed envelope into an apparatus, injecting a hardenable, liquid gel-catalyst mixture into the envelope through an inlet, and using a portion of a persons body to apply pressure to the envelope and allowing the mixture to harden while the pressure is being applied. The initially liquid mixture will conform to the shape of the body part which is applying the pressure, and once hardened will provide a product which is specifically shaped to the individual's body part. The product could be a shoe, a safety helmet, protective padding for various parts of the body, handles on tools and implements, and the like.

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: Footwear, in particular sports footwear, which includes a vamp associated with a substantially flat foot-supporting lower part or sole unit. This latter includes at least one portion formed of woven composite material having a part positioned in correspondence with the metatarsal region of the user's foot and a part positioned corresponding with the arch region of the user's foot, wherein the part of the portion present in the metatarsal region is flexible and enables the sole unit to flex during the use of the footwear and wherein part of the portion present in the plantar arch region is rigid.

Abstract: A shoe last and method for forming a shoe which is particularly constructed to be worn with and matingly interface with a wearer's custom-shaped sock. The shoe last includes a body having a backpart and a forepart connected to the backpart and extending forwardly therefrom. The last has a last bottom portion for abuttingly contacting and interfacing with a sole of a shoe. The last bottom portion has a bottom shape corresponding to the bottom shape of a custom-shaped sock when positioned on the foot of a wearer. The sole of a shoe formed from the last has a custom-contoured shape corresponding to and substantially mating with an overlying custom-shaped sock when positioned therein.

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: 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 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 for making a conformable device including a light cure material for use in functional relation with an article of footwear in order to enhance conformance or fit, support, comfort, and cushioning. The present invention can serve to accommodate the unique anatomical features and characteristics of an individual wearer and finds application within numerous types of articles footwear (44).

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: 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 cushioning or padding body for insertion into footwear, a method of manufacturing the body and a method for the simultaneous manufacture and exact fitting of the body to the respective shape of a corresponding part of the foot of the wearer are related. The body comprises a plurality of individual foam material beads alone or a mixture of a plurality of individual foam material beads and a resiliently cushioning, thermoplastically non-deformable plastic material. The beads are each provided with a closed surface and each is generally impermeable to air. The beads are fixed in their position relative to each other by the effect of that.

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: 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 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 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 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 inside boot sole, comprising separate support zones distributed under the surface of the foot, at least two support zones (3, 4) having different mechanical characteristics and each extending at most from the heel (5) to the front end (6) of the sole on both sides of the dividing line (10) located near the median longitudinal axis (7) of the sole.

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 rigid orthotic insert made of a plurality of layers bonded to one another, with each of the layers comprising parallel fibers, some of which are graphite. Along an outside edge of the insert, there is a layer of reinforcing graphite fibers. This arrangement desirably alleviates certain force patterns when high heels are worn, and also adds to comfort.

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: An article of footwear is made by partially forming the article so as to comprise at least an upper (11) lasted to a first insole (12), arranging the partially formed article to fully expose the upper (or inner) surface of the first insole, preferably by turning the partially formed article inside out, and moulding a shock absorbing or resilient second insole (15) of elastomeric, preferably visco-elastic, material onto the exposed surface of the lasting insole. An outsole (13) is applied to the article at some stage, preferably before the second insole is moulded in.

Abstract: A rigid orthotic insert made of layers bonded to one another, with each of the layers being made of graphite fibers positioned parallel to one another. At least one of the inserts is made of several sections, with some of the sections having the fibers oriented at different angles, thus causing a desired pattern of transmission of forces through the insert.

Abstract: A rigid orthotic insert having an elongate reinforcing member at a localized position in the orthotic. The reinforcing member comprises a fiberglass reinforced plastic core, around which is wrapped several layers of a sheet made of graphite fibers impregnated with resin. The graphite fibers are oriented with the lengthwise axis of the reinforcing member, and these are formed as an integral part of the insert.

Abstract: An orthotic insert formed of a plurality of layers bonded to one another. Some of the layers are made from fiberglass reinforced plastic, having the fibers oriented at 45.degree. from the longitudinal axis. At least one of the layers is made of parallel graphite fibers, having an axis of orientation offset from the longitudinal axis of the insert.

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.

Abstract: An orthotic appliance and a method of making same in which the appliance is for use between a foot and a shoe, boot or the like and includes an insert which is to be placed between the foot and the boot, the insert is to be custom formed to correspond to the contour of an individual's foot. The insert is initially heated until its volume expands, thereafter the insert is placed on a platform and the two are adjoined to the foot. A vacuum bag is slid thereover, a vacuum is formed within the bag, and thereafter the insert takes the configuration of the bottom face of the foot. Additionally, foot pressure may be applied to augment the degree of conformation of the insert to the foot, and in other embodiments an additional heel insert is placed below the major insert, and a crest piece is placed between the ball and toe area of the insert on the underside thereof so that this additional material can be bonded to the major insert and also conform to the user's foot.

Abstract: An orthotic insert for use in various types of foot gear consisting of a first blank and a second blank fused together. The first blank is a flexible pad generally contoured to the bottom of a person's foot and the second blank is more rigid and contoured to the calcaneal and arch regions of a specific individual's foot. In combination the first and second blank form an orthotic insert which offers support to and is resiliently deformable in the heel area and flexible in the toe area thus emulating the requirement of the human gait cycle.

Abstract: An orthotic insert for use in various types of foot gear consisting of a first blank and a second blank fused together. The first blank is a flexible pad generally contoured to the bottom of a person's foot and the second blank is more rigid and contoured to the calcaneal and arch regions of a specific individual's foot. In combination the first and second blank form an orthotic insert which offers support to and is resiliently deformable in the heel area and flexible in the toe area thus emulating the requirement of the human gait cycle.