Materials & Pads

The shells, top covers, cushioning layers and pads we build with, and where each one fits.

Shells

Shell & Base Materials

MaterialWhat it isTypical use
Polypropylene

Polypropylene

Semi-rigid thermoplastic and the functional-shell standard. Tough, heat-adjustable and durable, with thickness matched to patient weight and activity level.

Functional orthotics · RX UCBL · AFOs

Composite Carbon Fiber

Composite Carbon Fiber

Carbon fibers set in a polymer resin: very thin, very stiff and lightweight. Holds its shape in low-volume shoes where a polypropylene shell will not fit.

Dress shoes · Cleats · Sport devices

EVA

EVA

Soft, accommodative closed-cell foam Conforms to the foot and cushions bony prominences with minimal correction. Available in 35, 45, 65 durometer.

Diabetic inserts · Arthritic and geriatric feet · Full-contact cushioning

Rubber Cork

Rubber Cork

Cork granules bonded in rubber. Lightweight, grindable and shapeable, with a firm feel that resists compression set.

Rearfoot and forefoot posting · Heel lifts · Extensions

EVA Cork

EVA Cork

Cork blended into an EVA base. Lighter and more resilient than rubber cork, with a slightly softer feel underfoot.

Posting and fills · Lifts · Accommodative builds

Covers

Top Covers & Cushioning

MaterialWhat it isTypical use
Neoprene

Neoprene

Comparable to Spenco®, Urethane-based, 360° stretch cover with strong rebound and stability. Durable, wipes clean and resists wrinkling. Stocked in 1/16" and 1/8", black.

Sport and high-friction covers · Active patients

EVA

EVA

General-purpose mid layers, Soft, flexible closed-cell foam with low-temperature toughness and stress-crack resistance. Available in 1/16", 1/8"; Marine Blue, or swirl.

General-purpose top and mid layers

Perforated EVA

Perforated EVA

The same EVA foam with perforations that let air and moisture move through the cover. Available in 1/16", 1/8"; black.

Warm climates · Athletic use · Moisture control

Accuzote (Zote Foam)

Accuzote (Zote Foam)

Comparable to Plastazote®, Cross-linked polyethylene cushioning foam that holds its loft and cushion quality far longer than open-cell foams. Heat-moldable for total-contact layers. Available in 1/16" to 1/8".

Diabetic and neuropathic feet · Total-contact top layers · Pressure redistribution

Urethane

Urethane

Comparable to Poron® and PPT®, high quality open-cell urethane foam with high rebound and shock absorption. Stocked in 1/16", 1/8"; blue.

Heel pain · Fat-pad atrophy · Impact and pressure relief

Vinyl

Vinyl

Thin (1 mm), smooth supportive cover with excellent bottom-out resistance. Easy to clean and adds almost no bulk.

Dress shoes · Low-volume footwear · Hygiene-critical patients

Perforated Vinyl

Perforated Vinyl

Vinyl cover with perforations for airflow while keeping the same thin, durable, wipe-clean surface.

Dress orthotics needing breathability

Suede (Nonwoven)

Suede (Nonwoven)

Synthetic nonwoven suede. Soft, low-friction and moisture-absorbing, with a matte finish that does not slip in the shoe.

Bottom covers · Dress orthotics · Sock-wearing patients

Leather

Leather

Genuine leather top cover. Breathable, conforms to the foot over time and offers a premium look and long service life. Condition with mink or saddle oil.

Dress orthotics · Longevity · Patients who prefer natural materials

Additions

Pads & Additions

AdditionWhat it doesConsider for
Met Bar

Met Bar

Transverse bar placed just proximal to the metatarsal heads to offload all five at once.

Generalized metatarsalgia · Diffuse forefoot pain

Met Pad

Met Pad

Dome-shaped pad behind the 2nd–4th metatarsal heads that restores the transverse arch and spreads the metatarsals.

Metatarsalgia · Morton's neuroma · Capsulitis

Heel Pad

Heel Pad

Cushioned layer under the heel, with an optional cutout, that absorbs impact and softens the calcaneus.

Plantar fasciitis · Heel spur · Fat-pad atrophy

Horseshoe Pad

Horseshoe Pad

U-shaped heel pad that surrounds and floats the central heel or spur site.

Heel spur · Plantar fasciitis · Calcaneal bursitis

Neuroma Pad

Neuroma Pad

Small teardrop pad placed between the 3rd and 4th metatarsal heads to spread the metatarsals and relieve nerve compression.

Morton's neuroma · Intermetatarsal bursitis

Toe Crest Pad

Toe Crest Pad

Raised ridge under the toe sulcus that supports toes 2–5 and takes pressure off the distal tips.

Hammer and claw toes · Distal toe-tip pressure

Dancer's Pad

Dancer's Pad

Forefoot pad with a first-MTP cutout that offloads the first ray and sesamoids.

Sesamoiditis · Hallux limitus and rigidus · Turf toe

Scaphoid Pad

Scaphoid Pad

Medial arch (navicular) pad that adds longitudinal arch support to an existing device.

Flatfoot · Posterior tibial tendon dysfunction · Arch fatigue

Met Balance Pad

Met Balance Pad

Pad with a cutout that lifts the adjacent metatarsals to float a single painful metatarsal head.

Isolated met-head pressure · Plantar plate tear · Callus or ulcer offloading