
Orthotics are shoe or heel inserts prescribed by a doctor to help with various foot problems. Rigid orthotics are typically made of hard plastic or carbon fibre and are used to restrict abnormal foot movement, offering more stability and support. However, they may be uncomfortable and take longer to break in. On the other hand, soft orthotics are made of materials like EVA foam and gel, providing cushioning, shock absorption, and pressure relief. They are more flexible and comfortable but may not address the structural support needs of the feet. So, how can you make a hard plastic orthotic more cushioned and comfortable?
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What You'll Learn

Using foam for cushioning and support
Orthotics are available in both rigid and soft varieties. While rigid orthotics are made from hard plastic or carbon fibre, soft orthotics are made from materials like EVA foam and gel. Soft orthotics are ideal for providing cushioning and support, improving shock absorption, increasing balance, and relieving pressure. They are also recommended for individuals with diabetes, arthritis, or foot deformities.
If you have a hard plastic orthotic, you can add cushioning by using foam. Foam orthotics can be made from expanded polyethylene, EVA (ethylene vinyl acetate), or silicone. EVA foam sheets are available in craft stores and can be used to add cushioning to your orthotics. You can also create custom foam orthotics by casting them from old ones using silicone and a plastic mould. This process involves creating a mould of your orthotic, mixing and pouring liquid silicone into the mould, and then demoulding the new foam orthotic.
When creating custom foam orthotics, it's important to consider the density and stiffness of the foam. A mixture of rigid and flexible foam can be used to achieve the desired stiffness, similar to the original orthotic. Trial and error may be necessary to find the right combination and amount of foam for your needs. Additionally, consider the pour direction, vents, and alignment to ensure a successful cast.
Foam orthotics provide excellent cushioning, support, and pressure relief. They can be customised to fit your specific needs and preferences. By using foam, you can enhance the comfort and functionality of your hard plastic orthotics.
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Gel for shock absorption and balance
Gel insoles are a great option for those seeking shock absorption and balance. They are designed to provide superior cushioning for the heel and forefoot, absorbing impact with every step and reducing strain and pressure on sensitive areas of the foot. The contoured gel layer offers enhanced support for the heel while gently supporting the arch, promoting better stability and balance during movement.
Gel insoles are widely compatible with many types of footwear, including sports shoes, boots, casual shoes, and work shoes. They can be easily trimmed to ensure a perfect, customized fit, and their textured base grips securely inside shoes, preventing slippage for enhanced stability and comfort.
Gel insoles are also washable and reusable, making them a convenient and cost-effective choice. They are lightweight, flexible, and breathable, with anti-slip and anti-odor properties, ensuring comfort and support for the wearer.
For those seeking a softer, more flexible option to support their feet, gel insoles are an excellent choice. They mold to the unique shape of the foot, providing superior comfort and energy return, and are ideal for those experiencing foot fatigue or discomfort caused by conditions such as plantar fasciitis, heel pain, or arch pain.
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EVA foam for a sturdy, crack-resistant option
EVA foam is a sturdy yet flexible material, making it an excellent choice for those seeking a durable option to cushion their hard plastic orthotics. EVA stands for ethylene-vinyl acetate, and it is a closed-cell, high-density foam with a soft, rubbery feel. Its surface compresses when pressed but quickly regains its shape, making it ideal for orthotics as it provides both cushioning and support.
One of the key advantages of EVA foam is its resistance to cracking. This quality ensures that your orthotics maintain their shape and performance over time. Additionally, EVA foam is lightweight and buoyant, making it a comfortable option for orthotics. Its shock-absorbing properties further enhance its comfort and make it a popular choice for sports equipment and protective gear.
EVA foam is also known for its water-resistant properties, making it suitable for outdoor use and wet conditions. This feature can be especially useful if you plan to wear your orthotics in environments where they may be exposed to moisture. The foam is also UV-resistant, which helps extend the lifespan of your orthotics by protecting them from environmental factors.
The versatility of EVA foam allows manufacturers to customize its density, hardness, and colour, making it adaptable to different orthotic needs. Its ease of moulding, cutting, and shaping facilitate design flexibility. EVA foam is also cost-effective compared to some other specialized materials, making it a more affordable option for consumers.
Overall, EVA foam is a sturdy and crack-resistant option for cushioning hard plastic orthotics. Its combination of durability, flexibility, and comfort makes it a popular choice for those seeking a long-lasting and supportive orthotic solution.
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Semi-rigid orthotics for a balance of cushioning and motion restriction
Orthotics are shoe or heel inserts prescribed by a doctor to help with various foot problems. They are used to correct foot deformities, help feet or ankles function better, and reduce the risk of injury. Orthotics can be soft, semi-rigid, or rigid.
Semi-rigid orthotics are made of composite layers that contain both soft and rigid insole materials. They provide the cushioning benefits of a soft insole and the motion restriction effect of a rigid insole. Semi-rigid orthotics are particularly useful for athletes who experience pain during training. They are also good for people with flat feet, especially congenital flat feet.
Rigid orthotics are typically made of hard plastic or carbon fibre and provide more stability and support. They are often used to treat plantar fasciitis due to flat feet, as they offer rigid arch support and help restrict or control abnormal foot movement to ensure correct alignment. Rigid orthotics may also be recommended for foot, leg, thigh, and lower back pains, as they sit flush against the feet and take the load off. However, they may be less comfortable than softer orthotics and can take longer to adjust to.
Soft orthotics, on the other hand, are made of materials like EVA foam and gel. They are best for providing cushioning, improving shock absorption, increasing balance, and relieving pressure. Soft orthotics are more flexible because they bend with the feet. They are recommended for individuals with diabetes, arthritis, or foot deformities such as bunions or hammertoes. Soft orthotics can also help with heel pain by moulding to sore spots and providing arch support.
The choice between semi-rigid, rigid, or soft orthotics depends on the individual's specific needs and the recommendation of a podiatrist or certified pedorthist.
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When to use hard plastic orthotics
Hard plastic orthotics are typically used to treat a variety of foot conditions and can be recommended by podiatrists as part of a treatment plan. They are often used to correct abnormal foot movements and provide more stability and support. Hard plastic orthotics are ideal for those who require rigid arch support, such as individuals with plantar fasciitis or flat feet. This type of orthotic can also help restrict abnormal foot movement, ensuring correct alignment. Additionally, they are recommended for treating foot, leg, thigh, and lower back pain by redistributing weight and pressure.
Hard plastic orthotics are usually made from rigid materials like plastic or carbon fibre, and they offer more stability and support compared to softer alternatives. While they may take longer for your feet to adjust to, hard plastic orthotics can provide the necessary structure and alignment for individuals with specific foot conditions. It is important to note that these orthotics may crack or break if excessive force is applied, so it is crucial to inform your podiatrist about any sports or activities you engage in to choose the appropriate material.
When deciding between hard and soft orthotics, it is essential to consider necessity and function rather than material preference. Hard plastic orthotics are ideal for individuals who require more support and stability, especially those with conditions like plantar fasciitis or flat feet. They are also suitable for individuals experiencing foot, leg, thigh, or lower back pain. By sitting flush against the feet, hard plastic orthotics can redistribute weight and provide relief from pain.
Additionally, hard plastic orthotics have the advantage of not being influenced by the stiffness or support of the shoe. Unlike soft orthotics, they do not depend on the stiffness of the sole and can provide consistent support regardless of the footwear. This makes them a reliable option for individuals who need consistent support throughout the day, regardless of their shoe choice.
While hard plastic orthotics offer stability and support, they may not be as comfortable as soft orthotics initially. Hard orthotics can take longer to break in and may require adjustments to ensure comfort. However, with time, your body can adjust to the support they provide, and they can become quite comfortable. It is important to work with a practitioner to determine the best type of orthotic for your specific needs and to make any necessary adjustments to ensure optimal comfort and functionality.
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Frequently asked questions
Hard plastic orthotics are used to limit abnormal foot movements and provide more stability and support. They are often used to treat plantar fasciitis due to flat feet, as well as foot, leg, thigh, and lower back pains.
Hard plastic orthotics may take longer to get used to and can be uncomfortable for some people. They may also crack or break if high amounts of force are applied to them.
Soft orthotics are more flexible and provide better cushioning. They are recommended for individuals with diabetes, arthritis, or foot deformities such as bunions or hammertoes. Soft orthotics can also help relieve heel pain by moulding to painful areas.
Soft orthotics may not provide enough structural support for the foot. They may also require more effort to stabilise the foot with each step, which can be tiring over longer distances.











































