Patent ID: 7625349

Claim:
A method for making a custom made foot orthosis ( 10 ) for engagement inside a footwear (F) and for conformingly fitting against a bottom surface (P) of a foot of a person for correcting anatomic biomechanical deficiencies of the foot and ensuing body deficiencies of the person, said method comprising the steps of: a) producing a corrective positive mold ( 32 ) of the bottom surface (P) of the foot based on a specialist patient assessment and clinical measurement deficiencies of the foot to correct for the anatomic biomechanical deficiencies of the foot; b) thermoforming a first strip of moldable synthetic rubber material onto the corrective positive mold ( 32 ) to produce a thermoformed flexible top layer ( 12 ) sized for conformingly fitting against the bottom surface (P) of the foot; c) thermoforming a moldable core strip onto the top layer ( 12 ) to produce a thermoformed flexible reinforcement core layer ( 14 ) sized for having a posterior end ( 16 ) in alignment with a mid anterior plantar prominence (K) of a calcaneus bone (C) of the foot, and an anterior end ( 18 ) in near alignment with metatarsalphalangeal joints (J) defined between metatarsal bones (M) and phalange bones (T) of the foot; d) thermoforming a second strip of moldable synthetic rubber material onto the top layer ( 12 ) and the core layer ( 14 ) to produce a thermoformed flexible bottom layer ( 20 ), the core layer ( 14 ) being more rigid than the top and bottom layers ( 12 , 20 ); and e) grinding the top and bottom layers ( 12 , 20 ) to further correct for the anatomic biomechanical deficiencies of the foot; thereby, when the foot orthosis ( 10 ) is used by the person, the top and bottom layers ( 12 , 20 ) cushion walking impacts on a calcaneus spine (S) of the calcaneus bone (C) of the foot, while the core layer ( 14 ) transmits the walking impacts to a foot surface extending from the mid anterior plantar prominence (K) of the calcaneus bone (C) of the foot to near the metatarsalphalangeal joints (J).