Method and apparatus for making corrected custom foot molds

A method for producing a corrected mold for a foot from a molding material, said foot having a forefoot portion and a rear portion, said method comprising the steps of:

• supporting the foot on resilient cushion means having a rear section with a first thickness for supporting said rear portion and a front section with a second, smaller thickness for supporting said forefoot portion such that said foot is positioned on said resilient cushion means with said forefoot portion being positioned lower than said rear portion thereof and being relatively immobile with respect to said rear portion thereof and such that said rear portion supports its respective portion of full body weight in a floating manner;
• supporting the rear portion of the foot on said rear section in a floating manner, with said rear section being deformable throughout the entire first thickness thereof to provide the support in said floating manner;
• adjusting the position of the rear portion of the foot on said resilient cushion means so that said foot is in a substantially neutral position;
• accurately aligning a knee with respect to said foot when the foot is positioned on said cushion means by means of alignment means;
• and
• associating said alignment means with said foot to ensure a substantially ideal weight bearing position of said knee with respect to the foot;
• and
• making a mold of said adjusted foot from said molding material positioned between said foot and said resilient cushion means.

Apparatus for producing a corrected mold for a foot from a molding material, said foot having a rear portion and a forefoot portion with a ball portion, said apparatus comprising:

• resilient cushion means for substantially immobilizing the ball portion and providing a floating action for the rear portion thereof when said foot is supporting its respective portion of full body weight, said resilient cushion means having a rear section with a first thickness for supporting said rear portion and a front section with a second, smaller thickness for supporting said forefoot portion, said rear section being deformable throughout the entire first thickness thereof to provide the floating action, the second thickness being sufficiently small such that said ball portion completely compresses said front section at the respective position of the ball portion to provide said substantial immobilization, wherein the position of the rear portion of the foot on the resilient cushion means is adjusted so that said resilient cushion means adopts a corrected contour of the foot and said corrected mold is produced from said molding material positioned between said resilient cushion means and said foot;
• and
• alignment means for positioning a knee corresponding to said foot such that said knee is positioned in accurate alignment with the foot when said foot is positioned on said resilient cushion means and such that said foot is in a substantially neutral position on said cushion means.