Always Custom, Never Utilizing a Library System.

While patient conditions may be similar, each foot is unique – making it imperative for every orthotic to be custom to every single patient.  This is why Allied OSI Labs never utilizes a library system (like many other labs do).

While the products that stem from some labs which use sizing libraries are considered custom, it’s fair to say that not each patient is receiving their own, unique negative cast – every time; and that the orthotics are actually semi-custom.

Unfortunately, some labs manufacture orthotics using a sizing library system without disclosing or making it clear to their clients. These semi-custom orthotics have the potential to reduce positive patient outcomes in comparison to true custom orthotics which are manufactured using a unique cast every time.

Our Process

1. CAST TYPES
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.

2. 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.

3. 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.