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Casting Instructions
Our easy to follow instructions for casting CarbonPro Orthotics.
 
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Casting Instructions

Figure 1: In the frontal plane mark a line along the lower ½ of the tibia that aligns with the 2nd digit (this will give a good indication of the subtalar neutral position). Sit patient on a chair with legs 90 degrees to floor. Place left foot on left side of foam box. Place heel about 1 inch from the back edge of box and centre foot in the middle of the foam.
Figure 2: Place left thumb in the inner-space of the navicular & talus bones on the left foot. And index finger on the left side of the talus. This way you can feel for neutral position. Next turn left box lid counter-clock wise, which will pronate the heel or clockwise which will supinate the heel. Then stop turning the box when you find that the navicular & talus are properly aligned in subtalar neutral.
Figure 3: Picture shows heel and in-step in neutral position. In 80% of all feet you will find that the fore foot has a varus deformity. The first, second, & third metatarsals will be above the top of the foam (Drawing in figure 3) Later when the fore foot is pushed down you must keep the angle all the way down to bottom of box. (See figure 5)
Figure 4: After setting the foot in neutral the right hand should still be in place on in-step. Then place your left hand on the patients left knee. With both hands push knee and in-step straight down until heel is at the bottom of the box. (Make sure the anterior lines are still in good alignment).


Figure 5: The left hand should still be on left knee. Place right back part of palm over the heads and if your hand is narrower than the foot be sure to use the lateral part of palm on the fifth metatarsal and the rest of palm on 4, 3, & 2. This is in order to feel the fifth metatarsal when it stops at the bottom of the box. Next push all of the metatarsal heads down keeping your palm at the same angle the fore foot was in when you set the foot in neutral. (see third picture) until the fifth metatarsal stops approximately 2 inches at the bottom of the box. Do not roll across the heads and push the first metatarsal down.
Figure 6: Push the toes down.
Figure 7: Place the index finger on the cuboid and push a little just to seat it.
Figure 8: Note: Heel is approximately 2 inches down in the foam and the fifth metatarsal is 2 inches down, and the in-step is in line with the medial side of the leg. (see figure 4)
Figure 9: Cast right foot on right side of box using left thumb on navicular & talus inner-space and repeat all the previous steps
Figure 10: Shows a proper cast, the heel and the lateral side of the fifth metatarsal is approximately 2 inches down at the bottom of the foam. And the first metatarsal is ¼ inch off the bottom of the box, which matches the fore foot deformity when the foot was first set in neutral as in figure 3. It's important to keep your palm at the angle the fore foot is in when the heads are pushed down.
Figure 11: The plaster cast shows where the ¼ inch post was added into the cast to fill in the missing space. This balances the varus in the fore foot, so your patient can toe off evenly and walk more in the middle of the foot. It helps to maintain good alignment in the knee and hip.
Figure 12: When an impression is taken by simply stepping into the box, it is impossible to know how much to raise and correct the foot. The reason you must cast in subtalar neutral is as equally important as the reason for giving your patient an orthotic. You want to control and correct the patient's foot. For the orthotic to be made properly, we must receive an accurate impression of the foot. When you send in a corrected foot we can make an orthotic to compensate for the corrections.
 
 
 
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