Method for dye-sublimation printing an orthotic substrate and orthotic product made thereby

A method for manufacturing an orthotic product having a dye-sublimation printed decorative design comprising:

• a dye-sublimation printing part comprising the steps of:
• providing an oven heated to a first temperature;
• placing a moldable orthotic substrate inside the oven;
• heating the moldable orthotic substrate to a second temperature;
• positioning a transfer paper substrate having a digitally printed decorative design on the moldable orthotic substrate with the digitally printed decorative design down and in contact with the moldable orthotic substrate to form a duo-layered substrate;
• and
• sublimating the digitally printed decorative design without pressure from the transfer paper substrate to the moldable orthotic substrate upon formation of the duo-layered substrate, wherein all sublimating is performed without applying pressure other than optionally rubbing the transfer paper substrate manually to ensure that the ensure digitally printed decorative design transfers to the moldable orthotic substrate;
• and
• a manufacturing part comprising the steps of:
• wrapping the printed moldable orthotic substrate around an orthotic mold;
• applying a vacuum to the orthotic mold to conform the printed moldable orthotic substrate to the orthotic mold to form an orthotic product.