Customized orthopedic sole-insert and method for making

A method for creating a sole insert which is custom fit to the plantar aspect of a wearer's foot comprising the step of:

• providing a bottom shell comprising a top surface, a bottom surface, an arch area, an aperture extending from said top surface to said bottom surface, a plurality of canals emanating away from the aperture on said top surface, and where said aperture is positioned through said arch area;
• providing a formable layer comprising a material which will permanently harden upon contact with an accelerant;
• providing a top cushion;
• disposing said formable layer between said top surface of the bottom shell and the top cushion;
• connecting the circumference of said top cushion to said bottom shell so that said formable layer is sealed between said top cushion layer and said bottom shell;
• providing a sufficient amount of accelerant;
• and,
• injecting said sufficient amount of accelerant into the formable layer and subsequently exerting downward forces upon said top cushion by a wearer's foot for a sufficient period of time, where said formable layer will confirm to the plantar aspect of said wearers foot and permanently harden.

A method for customizing a sale-insert comprising the steps of:

• selecting an insert from a selection of inserts having various sizes, widths and arch heights, said insert comprising:
• a bottom shell having a top surface, a bottom surface, an aperture extending from said top surface to said bottom surface, a plurality of canals emanating away from the aperture on said top surface;
• a formable layer comprising a material which will permanently harden upon contact with an accelerant;
• a top cushion, the circumference of said top cushion connected to said shell so that said formable layer is sealed between said top cushion layer and said shell;
• means for delivering a sufficient amount of accelerant to permanently harden said formable layer;
• thereafter, inserting said insert into a wearer's shoe;
• thereafter, inserting the wearer's foot into the wearer's shoe upon said insert and applying a downward force upon the insert;
• thereafter, maintaining a downward force upon said sole insert until said formable layer substantially hardens;
• and,
• separating the top cushion and hardened formable layer from the bottom shell, the top cushion and hardened formable layer now collectively referred to as a customized sole insert.