19/01/2026
How to make a handmade orthotic - step 1
Once the negative cast is poured and becomes a positive cast, the fist step is a cast evaluation. During this process, we will:
- Ensure the casts are labelled correctly and match the prescription.
- Assess the quality of the casts to check for any blemishes/damage and the contours of the cast are true and representative of the foot.
- Balance the casts to determine the rearfoot to forefoot relationship (ie. intrinsic forefoot valgus or forefoot supinatus) and medial longitudinal arch heights.
- Mark the 1st, 2nd and 5th MPJs. This will assist in determining the widths and lengths of each cast.
- Review the prescription. Should there be missing information or we require clarity on the instructions, one of our podiatrists will contact the prescribing podiatrist to seek further instructions or provide prescription advice.
This cast evaluation is performed by one of our podiatrists on every handmade order that comes through the lab. A process that ensures each order is customised. No shortcuts.
