Method for producing an individual patient-data-based modular-structure foot sole last and for determining the materials and the structure of an individual patient-data-based insole

A method for producing an individual scalable orthopedic insole for a patient or sportsman, said insole having a plantar structure, the method comprising:

• determining an actual value for a foot mould that represents a shape of a foot by reference to at least one of measured values and medical findings that have been obtained from a body of the patient or sportsman;
• comparing the actual value determined for the foot mould with one or more predefined desired values to determine an ideal scalable orthopedic insole last having a plantar structure for the patient or sportsman;
• selecting a consecutive sequence of modules from a set of pre-fabricated modules that most closely matches the ideal scalable orthopedic insole last determined for the patient or sportsman based on said compared value;
• constructing an individual scalable orthopedic insole last for the patient or sportsman by combining the selected modules in the consecutive sequence;
• heating a thermoplastic material;
• arranging the heated thermoplastic material on a plantar side of the individual scalable orthopedic insole last;
• covering the thermoplastic material on the plantar side of the individual scalable orthopedic insole last with a flexible cover of a vacuum press;
• and
• applying a negative pressure between an underside of the flexible cover of the vacuum press and the individual scalable orthopedic insole last, such that the thermoplastic material conforms to contours of the plantar side of the individual scalable orthopedic insole last and, upon cooling, forms the individual scalable orthopedic insole.