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How Custom Orthoses are Made: The Science Behind the Perfect Fit

Why One Size Definitely Doesn’t Fit All

When most people think of orthotics, they picture something you pick up at the pharmacy and slide into your shoe. But for people living with pain, instability, or long-term conditions, a custom orthotic is something completely different—and far more powerful.

At Steinmann Prosthetics & Orthotics, we design and build custom orthoses to support any joint. Our orthoses are guided by medical science, crafted by hand, and tailored to each person’s body and lifestyle.

Step 1: It Starts with How You Move

Before we begin designing anything, we take time to understand how your body moves. That means evaluating your posture, walking pattern (gait), joint alignment, and areas of stress or discomfort.

Orthoses are about improving the way your whole body functions. Whether it’s helping a child with toe-walking, supporting recovery after injury, or relieving diabetic foot pain, the goal is always to improve comfort, alignment, and mobility.

Step 2: Hands-On Casting for a Perfect Fit

At Steinmann Prosthetics & Orthotics, we rely on tried-and-true casting techniques to capture the exact shape of your upper or lower extremity – from your head, shoulders, arms, legs, or feet. Using plaster molds or fiberglass casting, we create a precise replica of your limb in its ideal position.

This method allows us to get detailed and accurate measurements that reflect how your body needs to be supported—not just when standing still, but during real-world movement.

Step 3: Choosing the Right Materials

Every orthotic device we make is built from materials chosen specifically for your needs. Some offer firm correction, others provide flexible support. We work with:

  • Thermoplastics for structure and control
  • EVA and foam layers for shock absorption
  • Leather or padded liners for added comfort
  • Reinforcements (if needed) for special support areas

The materials we use depend on the condition being treated and your personal activity level—whether you’re walking the dog, working on your feet, or chasing after grandkids.

Step 4: Custom Fabrication

Once the mold is complete and the design finalized, our fabrication team builds your orthotic by hand. Every cut, layer, and adjustment is done with precision—ensuring your orthotic is not just effective, but comfortable to wear every day.

Step 5: Fit and Follow-Up

At your fitting, we’ll check the orthotic’s fit and alignment in real time. We may make small tweaks to fine-tune comfort or support. And we’ll follow up to make sure it continues working well as your body adjusts—or as your needs change.

Better Movement Starts Here

Custom orthoses are more than just support—they’re a solution built specifically for you. If you’re dealing with pain, fatigue, or limited mobility, we’re here to help with expert care and a hands-on approach.

Ready to get started? Call or Text us today to schedule a consultation at our Las Cruces office or Alamogordo clinic —we’ll help you take the next step toward comfort and confidence.

The Custom Orthotic Process - In Pictures

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