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Comparison of 3D Digital Contact Casting versus Manual Foam Casting of the Feet for the Design and Fabrication of Custom Foot Orthoses

Kevin Hearon, DC Bio 

Journal of Vertebral Subluxation Research ~ January 31, 2008 ~ Pages 1-5



Objective: A clinical study of 22 patients each of whom underwent an examination of the feet, adjustment of the feet and then were held in neutral position to manually cast in foam, followed by automated 3D contact casting of the feet to determine whether patients responded better to custom orthotics designed by either method.


Methods: One week after the initial examination and foot casting, the patients received their first pair of orthotics, at which time their feet were adjusted again before wearing. They wore the first pair for one month, then the second pair with the same protocol. A questionnaire was then given to each patient to evaluate their experience with both sets of orthotics


Results: : Eleven questions of the fifteen required quantitative answers and were statistically analyzed. Three questions indicated statistically significant differences in favor of the 3D contact casting technique at a p-value of less than 0.05 with an additional two questions showing significance at a p-value of 0.10. Six questions showed no statistical difference between the foot casting techniques.


Conclusion: A statistical analysis demonstrated greater foot comfort and patient satisfaction from custom orthotics designed with the 3D digital casting technique over those designed using manual foam casting.


Key Words: Chiropractic, Vertebral Subluxation, Orthotics, Feet, Kinetic Chain, Casting

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