Suppliers to Medical Professionals since 1997

Custom Shoe Inserts and Orthotic Materials/Applications Information

Custom Shoe Inserts and Orthotic Materials/Applications Information


3 mm Copolymer Shell with EVA post & fill – Recommended for a wide variety of applications especially where biomechanical control is important or high patient weight is a factor. Custom shoe inserts and orthotics can be fabricated using any top cover and can incorporate additions like met pads/bars, extrinsic posts, spur cutouts and lifts. These orthotics are easily refurbished and modified. Expected durability of the shell is 5 years or more.

2 mm Copolymer Shell with EVA post & fill – Ideal for lighter weight patients (under 110 lbs.), geriatric and diabetic applications. Shell can also be filled with soft EVA foam for more a more accommodative device.

Nylon Shell with rearfoot post – Classic functional shell designed for all types of footwear including dress shoes. Especially suited for shoes that are slip lasted or not flat inside. Low volume, durable and waterproof.

Slim Nylon Shell with rearfoot post – Dress orthotic shell for women’s shoes and other very low volume footwear. Also ideal for ice skates and cycling shoes.

Kydex® – Used primarily for alpine ski boot orthotics. Full length plastic design can be extrinsically posted and can incorporate boot heaters. Not suitable for full gait applications.


3 mm HDC™ Foam (Perforated) – Perforated EVA blended foam used full length for shoes with removable sock liners. Waterproof, durable and comfortable with exceptional resistance to compression.

2 mm HDC™ Foam (Perforated) – Thin perforated EVA blended foam cover for lower volume footwear. Ideal for dress shoes, ice skates, cycling shoes and other snug fitting footwear.

3 mm Celmax™ – Durable Nylon® fabric covered open cell urethene for maximum cushion. Wicks moisture, resists ordors and has excellent memory.

2 mm Celmax™ – Thin, light and breathable top cover for use in dress and low volume footwear. Fabric covered cellular urethene.

1/8” Plastazote/Poron® – For diabetic arthritic patients requiring a highly cushioned and formable top cover. 1/16” pink Plastazote laminated to 1/16” Poron®.

Synthetic Leather – Thin, durable synthetic leather for 3/4 length dress shoe designs

Vinyl Covering – Can be used on top of 2mm and 3mm HDC Foam for added durability  or alone as a thin covering for dress orthotics.


All custom shoe inserts and orthotics designs incorporate a durable Viledon (non-woven fabric) bottom unless otherwise specified. Vinyl may be substituted upon request.


All custom shoe inserts and orthotics are available with added extrinsic fore & rear foot posts, metatarsal pads, metatarsal bars, heel spur cutout with pad and heel lifts. For Morton’s extensions we utilize carbon fiber plates at an additional charge. For areas of special accommodation (lesions etc.) please mark impressions.

Click here to view/print “Fabrication Order Form” as .PDF

Try out our lab for free! Special Offer

Simply order the A.C.T. Impression Pillow at the regular price of $60 and we will send you four sets of impression cores to get you started. The first pair of orthotics we fabricate will be sent to you at no charge. If you decide not to go forward, you can send back the impression pillow and cores and we will refund your purchase (excluding shipping).