# US 11,109,638 B2 · Orthotic and a method of making an orthotic

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- Number: US 11,109,638 B2
- Document ID: US11109638B2
- Status: Granted
- Kind: B2
- Application number: 15/526,487
- Filed: 2015-09-11
- Published: 2017-11-09
- Granted: 2021-09-07
- Earliest claimed: 2014-11-13
- Assignees: Peacocks Orthotics Limited
- Applicants: Peacocks Orthotics Limited
- Inventors: Iain Charlesworth; Chris Pluse; David Eardley; Leigh Wallace; Jari Pallari
- Web page: https://patentgrep.com/patent/US11109638B2

## CPC

- A43B 7/141: {having an anatomical or curved form}
- A43B 7/14: with foot-supporting parts
- A43B 7/1405: with pads or holes on one or more locations, or having an anatomical or curved form
- A43B 7/144: situated under the heel, i.e. the calcaneus bone
- A43B 7/1475: characterised by the type of support
- A43B 17/08: ventilated
- A43D 1/02: Foot-measuring devices (measuring the shape, pattern or size of the body for diagnostic purposes A61B5/103, e.g. measuring physical dimensions A61B5/107)
- A43D 1/025: {comprising optical means, e.g. mirrors, photo-electric cells, for measuring or inspecting feet}
- A61B 5/1036: {Measuring load distribution, e.g. podologic studies}
- A61F 5/14: Special medical insertions for shoes for flat-feet, club-feet or the like
- B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C 64/112: using individual droplets, e.g. from jetting heads
- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B29D 35/122: {Soles}
- B29D 35/124: {Heels}
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- B33Y 80/00: Products made by additive manufacturing
- A43D 2200/60: Computer aided manufacture of footwear, e.g. CAD or CAM
- A61B 5/1074: {Foot measuring devices}
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43D: MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
- A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D)
- A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

## Abstract

A method of making an orthotic is disclosed. The method includes the steps of taking measurements relating to a foot and then creating a digital representation of an orthotic on a display device based on said measurements. This digital representation of the orthotic having a heel portion for supporting a heel of a person and a distal portion located in front of the heel portion which can be divided into first and second distal portions. The thickness of the digital representation of the first and second distal portions is then varied such that one of the distal portions is thicker than the other. Finally, an additive manufacturing technique, using a substantially uniform material or materials, is used to create a physical version of the digital representation of the orthotic.

## Claims

### Claim 1

A method of making an orthotic, comprising the steps:
taking measurements relating to a foot;
creating a digital representation of an orthotic on a display device based on said measurements, the orthotic having a heel portion for supporting a heel of a person and a distal portion located in front of said heel portion, said distal portion being divided into a first and a second distal portion;
varying a thickness of the digital representation of the first and second distal portions such that said first distal portion is thinner than said second distal portion and said first distal portion includes no perforations formed therein and said second distal portion includes perforations; and
using additive manufacturing using a substantially uniform material or materials to create a physical version of the digital representation of the orthotic.

### Claim 2 (depends on 1)

The method according to claim 1, further comprising substantially defining said first and second distal portions by an axial line extending from a distal edge of said orthotic towards said heel portion and a transverse line extending transverse to said axial line.

### Claim 3 (depends on 2)

The method according to claim 2, wherein said axial line is located substantially between a first and second metatarsal of said measured foot.

### Claim 4 (depends on 2)

The method according to claim 2, wherein said axial line is located between 10% and 30% across the width of the orthotic from the medial edge.

### Claim 5 (depends on 2)

The method according to claim 2, wherein said transverse line is located substantially under the first metatarsal base of said measured foot.

### Claim 6 (depends on 2)

The method according to claim 2, wherein said transverse line is located at around 40% of the length of the orthotic from the distal edge.

### Claim 7 (depends on 2)

The method according to claim 2, wherein said transverse line is located substantially under the navicular bone of said measured foot.

### Claim 8 (depends on 2)

The method according to claim 2, wherein said transverse line is located at around 60% of the length of the orthotic from the distal edge.

### Claim 9 (depends on 2)

The method according to claim 2, wherein said transverse line is located adjacent said heel portion the first and second distal portions therefore extending along the whole length of the distal portion.

### Claim 10 (depends on 2)

The method according to claim 2, wherein said transverse line is located at around 80% of the length of the orthotic from the distal edge.

### Claim 11 (depends on 1)

The method according to claim 1, wherein the orthotic comprises an upper surface for engaging a foot and a lower surface for engaging an insole of a shoe, wherein said upper surface comprises a substantially continuous surface and the thickness of the first distal portion and the second distal portion are varied by varying the lower surface.

### Claim 12

An orthotic comprising:
a heel portion for supporting a heel of a person; and
a distal portion located in front of said heel portion, said distal portion being divided into a first and a second distal portion wherein said first distal portion is thinner than said second distal portion and said first distal portion includes no perforations formed therein and said second distal portion includes perforations.