Abstract: A method of making a foot-shaped layer, such as an insole member of a shoe using an apparatus which includes a top plate having an opening of a predetermined area and mutually adjacent bar-like measuring elements frictionally supported in an individually vertically movable manner within the opening. A sheet of thermoplastic is heated to a plasticized state and placed on the opening so as to cover the upper end surfaces of the measuring elements so that upon stepping on the sheet with a foot, the film and measuring elements thereunder move downward by amounts corresponding to the shape of the foot so that the film is molded to the shape of the foot. The molded film is then cooled and cut along the outline of the foot to obtain a layer which may be used to define the shape of an insole member.

Abstract: Multi-layer footwear formed of laminated layers of material which are sealed together with a polymeric glue used in the original manufacture of the footwear to secure the various layers of material together. The layers of material held together by polymeric glue are capable of being heated to a degree at which the footwear, when placed in a vacuum bag or compression chamber, is molded to adopt the shape of the foot inside the footwear under atmospheric pressure once pressure inside the bag is reduced or pressure in the compression chamber is increased. The footwear is heated to the point where the synthetic components of the layers of material are flexible under thermoforming conditions, but within a temperature range in which the polymeric glue continues to perform as an adhesive so that the sealed laminated surfaces do not separate.

Abstract: An apparatus for making a foot-shaped layer, such as an insole member of a shoe. The apparatus includes a top plate having an opening of a predetermined area and mutually adjacent bar-like measuring elements supported in an individually vertically movable manner under frictional resistance within the opening. A heating chamber is provided adjacent to the top plate for heating a sheet of thermoplastic therein to a plasticized state. In accordance with the method, a plasticized sheet of the film is placed on the opening so as to cover the upper end surfaces of the measuring elements so that upon stepping on the sheet with a foot, the film is molded to the shape of the foot. The molded film is then cooled and cut along the outline of the foot to obtain a layer which may be used to define the shape of an insole member.

Abstract: A method of custom manufacturing of shoes at a specified heel height is disclosed and includes forming a positive impression mold of the foot from a negative impression mold made with the foot oriented at the specified heel height. A sold impression form is provided having an upper surface shaped to correspond to the lower surface of the sole of a shoe with the specified heel height. The positive impression mold is located with its lower surface separated from the upper surface of the sole impression form by a distance approximating the desired sole thickness, after which a settable material adapted to harden to form a suitable sole is introduced into the space between the positive impression mold and the sole impression form. The sole impression form is then removed from the sole and the desired upper materials are attached to the sole to generally conform to the shape of the positive impression mold.

Abstract: A method to obtain corrected impressions of the foot so as to produce corrective soles including two or three superimposed rigid frames connected to a supporting structure secured by arms of different length joined to the supporting structure. Each frame is equipped with two flexible walls which, along with the frame, delimit a sealed enclosure filled with a granular material, the enclosure communicating with a suction 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: Apparatus for producing a corrected mold for a foot having a rear portion and a forefoot portion, includes a resilient cushion which relatively immobilizes the forefoot portion with respect to the rear portion thereof when the foot is supporting its respective portion of full body weight, the resilient cushion having a rear section with a first thickness and a front section with a second, smaller thickness for supporting the foot, wherein the position of the rear portion of the foot on the resilient cushion is adjusted so that the resilient cushion adopts a corrected contour of the foot; knee alignment cups for positioning a knee corresponding to the foot such that the foot is in a substantially neutral position when the foot is positioned on the resilient cushion and the knee is positioned in accurate alignment with the foot; and a molding material positioned between the foot and the resilient cushion for producing the corrected mold once the foot and the knee have been so adjusted.

Abstract: Disclosed is a method of fabricating a prosthetic member (112) having personalized features of the patient, and being formed to provide an individualized fit to the patient's extremity (18). A rigid jacket (30, 32) is first formed around the uninsured foot (10) and the amputated extremity (18). The limb characteristics are impressed into an alginate (44) lining within the jackets (30, 32). A stone material poured into the alginate lining (44) forms stone models (48, 50) of the patient's limbs. A wax preliminary model (64) is scuplted in the likeness of the stone foot model (48) and used to form final stone mold halves (100, 102). The contour of the stone extremity model (50) is adjusted according to the tissue texture of the patient to provide an individualized fit. A gelatinous silicone is injected inside the final mold (100, 102) and allowed to form around the extremity model (50) to thereby provide the body of the prosthetic member (112) and the conformal sleeve (132 ).

Abstract: A method for casting in situ an insole on a foot comprising the steps of preparing a mold defining an open top recess, providing a casting material in the recess, placing the foot inside the recess at a predetermined angle and position relative to the mold, engaging the casting material by the plantar surface of the foot, permitting the casting material to conform to the shape of the plantar surface of the foot, and permitting the casting material to harden.

Abstract: The invention relates to a method for forming an article by injection molding, such as a shoe, and comprises the formation of a mold (5) by coating a master pattern of the article with a pourable, heat-resistant molding compound, such as an epoxy resin or polyurethane. The master mold (5) so formed is secured in a mold casing (1) for an injection molding plant and molding material such as poly-vinyl chloride or polyurethane is injected to form the finished article. The master mold may be formed directly in the mold casing (1) to which it can be secured such as by mechanical securing and located means (6,7,8,) or by being adhered thereto. In an alternative embodiment of the invention, the master mold may be formed in a mold box and subsequently fitted into the mold casing (1) for reproduction of the article.

Abstract: A print is made of the sole of a foot in a block (1) of modelling clay. If necessary the print is corrected for orthopedic reasons. A rigid shape (23) is cast in the print, and after unmolding, the contour (26) of a sole to be made is marked on the shape in relief. The shape is then used to mark said contour in hollow form in the footprint. The block is then cut through along said contour and the central portion of the block is removed. The rigid shape is reinserted in the remaining peripheral portion of the footprint, and a sole is cast inside the peripheral portion and on the rigid shape. A first sole may be made in a single session in the presence of the patient. Thereafter, the rigid shape may be conserved, and used to make any subsequent soles that may be necessary without requiring the patient to be present.

Abstract: Apparatus for producing a corrected mold for a foot having a rear portion and a forefoot portion, includes a resilient cushion which relatively immobilizes the forefoot portion with respect to the rear portion thereof when the foot is supporting its respective portion of full body weight, the resilient cushion having a rear section with a first thickness and a front section with a second, smaller thickness for supporting the foot, wherein the position of the rear portion of the foot on the resilient cushion is adjusted so that the resilient cushion adopts a corrected contour of the foot; a stabilizer which aligns and stabilizes the knee corresponding to the foot to a predetermined alignment with respect to the forefoot portion of the adjusted foot when the foot is positioned on the resilient cushion; and a molding material positioned between the foot and the resilient cushion for producing the corrected mold once the foot has been so adjusted and the knee has been so aligned.

Abstract: An apparatus for producing custom orthotics includes a boundary wall encompassing a substrate pad and an overlying elastic skin to form an expandable interior chamber into which high density molding material is injected. A matrix of axially movable drive pins project through the pad and are urged upwardly into contact with the arch of the individual's foot to maintain the foot in properly aligned position during fabrication of the orthotic, the drive pins carrying a support bridge driven into conforming contact against the arch of the foot.

Abstract: A method of fixturing a shoe component from a block of suitable material by forming a first cavity in the block to expose a first surface of the component, applying a release agent to the first surface of the component, placing a body of a rigid material in the first cavity so as to extend over the entire first surface and into the surfaces of the block for adherence thereof to the block of material, repositioning the block, forming a cavity in the repositioned block to initiate the shaping of the shoe component, attaching the shoe component in its unfinished state to the body of rigid material, continuing the formation of the shoe component to completion to free it from connection with the block of material, and releasing the thus completed shoe component from the body of rigid material.

Abstract: After arranging on dual pans two thick strips of a deformable fiber-reinforced spongeous material and covering them with a liner made of an elastic cloth, a fluid polymer is poured into said pans which reacts to set and foam in a conveniently short time. During the setting time, the user keeps his/her feet fixedly inside the pans, to thus leave an impression which accurately reproduces the shape thereof. After setting, the deformable strips is bonded to the liner and retains the exact impression left by the foot.Successive trimming operations provide an insole taylored to fit the user's feet.

Abstract: A system for stiffening the shank of an insole uses a stiffener which is formed from an initially flexible and deformable strip of thermosetting resin, preferably mixed with reinforcing fibers such as fiberglass. A length of such shank strip material is applied onto the bottom of an insole and the insole, with the shank strip in place, is mounted in a special fixture. The fixture holds the strip on the bottom of the insole and also assures that the insole and shank strip will be held in the proper configuration, with the proper bend at the ball and the arch. With the shank strip and insole so held an external stimulus, such as radiant heat, is applied to the shank strip to activate and cure it in place on the insole bottom.

Abstract: A moldable article useful for making a form-stable article is described. The moldable article comprises a formable material that is a moldable polymeric or prepolymeric substance that can be cured to a form stable state and a curing agent, in close proximity to the curable substance but isolated therefrom, in a frangible container. The container containing the curing agent is initially flexible and is rendered frangible by special treatment which is part of the invention. In use, the frangible container is ruptured to release the curing agent and the moldable article, in a first configuration, can be shaped to a second configuration in which it is maintained until the formable material is cured sufficiently for it to be form-stable in the second configuration. The moldable article can be used to make molds, casts, support for a portion of the human or animal anatomy, or other articles with diverse utilities.

Abstract: Viscous, flowable, pressure-compensating fitting materials or compositions suitable for a variety of uses and applications, including, but not limited to, fitting pads for footwear or the like.

Abstract: Methods involving the use of high frequency heating means and temperature-compensating means to expand hollow, thermoplastic resinous microbeads in a controllable manner. The heat-expanded microbeads are suitable for use, for example, in providing viscous, flowable, pressure-compensating fitting materials or compositions.

Abstract: An orthocasting system for producing a negative mold of the bottom of the foot with the negative mold being used to produce a positive form which is then used as a base on which to form a rigid foot support insert which is constructed in accordance with a prescription prepared by a foot doctor.

Abstract: A method of making an insole having a heel positioner and an arch support, in which the positioning support for the heel is made in situ, in one discrete section of the foot support, and the arch support is then made, in situ, in a second discrete section.The first discrete section is made at the heel portion of the foot, in a manner so as to stabilize the plantar surface of the heel section of the foot under the cancaneous bone. This is for the purpose of eliminating, reducing or minimizing the rotation forces applied to the heel section of the foot by the weight of the body, which would normally tend to produce a pes valgus (outward bending) or a pes varus (inward bending) condition, as well as stabilizing the anterior - posterior position of the leg in its function of bearing body weight.