Allied OSI Labs accepts plaster casts, foam casts, as well as digital casts from the Tom Cat Scanner and our very own Allied OSI Labs iPad Scanner.
CAD/CAM DIGITAL CORRECTIONS
When our lab receives a plaster or a foam cast, each is then digitally scanned in our lab in order to be “cast corrected” in our computer software (CAD/CAM), creating the exact coordinates of the patient foot for custom orthotic milling. This digital scan is then stored in Allied OSI’s database for future patient orders or duplicate pair orders.
MILLING & SHELL MOLDING
The milling process is a technological wonder. Using the CAD/CAM corrections, the milling machine produces a corrected physical mold of the patient’s foot. Then, the shell material for the desired custom orthotic is placed over the mold, heated at extremely high temperatures in order to shape the material to fit the corrected patient mold. If an “arch fill” is requested, the plaster is added to the corrected cast before the shell material is heated/molded.
GRINDING AND POSTING
After the shell material (i.e. polypropylene) is cooled and removed from the mold, it goes into grinding and posting. This is the hand-crafted process of matching the orthotic to the prescription and order form requests.
ACCOMMODATIONS AND COVERS
Once the shell mirrors the physician prescription, accommodations like metatarsal pads, Morton’s extensions, horseshoe pads, ect. are trimmed and added. Finally, top covers and bottom covers are hand-glued and trimmed to precise, requested specifications detailed on the order form.