A method of forming a castless orthotic for a patient's foot in need thereof. The method comprises preparing an orthotic template for the foot wherein the template extends between a heel end and a toe end. In preparing the template the steps of attaching a three-quarter length or full length upper thermoplastic material to a or three-quarter length lower thermoplastic material, or providing a thermoplastic material having a variable thickness such that said thickness decreases from said heel end to said toe end is provided. Then attaching an outer lower layer to the lower thermoplastic material and attaching an outer upper layer to the upper thermoplastic material, or attaching an outer layer to each face of the variable thickness thermoplastic material and heating the prepared orthotic template for a predetermined period of time at a predetermined temperature to soften the orthotic template. A wrap is then placed on top of the foot foam and the foot of the patient is placed on top of the wrap and foot foam. The patient's foot is lifted and the heated orthotic template is placed on top of the the wrap and then placing the patient's foot on top of the heated orthotic template. The wrap is placed about the longitudinal axis of the foot to retain the heated orthotic template intermediate the sole of the foot and the foot foam whereby the sides of the orthotic template are particularly supported by the wrap. The method further includes ensuring the foot is positioned over a cuboid support and a medial longitudinal arch support wherein the cuboid support is disposed on the outside of the bottom of the foot and the cuboid support is moved to push the foot upwardly until a resistance is felt, and where the foot is also positioned over the medial longitudinal arch support which is then pushed and pulled upwardly until the foot is moved into a neutral position or if it is unable to be translated or rotated due to until it reaches its end range of motion. At this time, the heel of the patient's foot is lifted to place their weight substantially on the front of their foot and a coolant is applied to at least the heel end of the orthotic template.

A method of forming a castless orthotic for a patient's foot in need thereof. The method comprises preparing an orthotic template for the foot wherein the template extends between a heel end and a toe end. In preparing the template the steps of attaching a three-quarter length or full length upper thermoplastic material to a or three-quarter length lower thermoplastic material, or providing a thermoplastic material having a variable thickness such that said thickness decreases from said heel end to said toe end is provided. Then attaching an outer lower layer to the lower thermoplastic material and attaching an outer upper layer to the upper thermoplastic material, or attaching an outer layer to each face of the variable thickness thermoplastic material and heating the prepared orthotic template for a predetermined period of time at a predetermined temperature to soften the orthotic template. A wrap is then placed on top of the foot foam and the foot of the patient is placed on top of the wrap and foot foam. The patient's foot is lifted and the heated orthotic template is placed on top of the the wrap and then placing the patient's foot on top of the heated orthotic template. The wrap is placed about the longitudinal axis of the foot to retain the heated orthotic template intermediate the sole of the foot and the foot foam whereby the sides of the orthotic template are particularly supported by the wrap. The method further includes ensuring the foot is positioned over a cuboid support and a medial longitudinal arch support wherein the cuboid support is disposed on the outside of the bottom of the foot and the cuboid support is moved to push the foot upwardly until a resistance is felt, and where the foot is also positioned over the medial longitudinal arch support which is then pushed and pulled upwardly until the foot is moved into a neutral position or if it is unable to be translated or rotated due to until it reaches its end range of motion. At this time, the heel of the patient's foot is lifted to place their weight substantially on the front of their foot and a coolant is applied to at least the heel end of the orthotic template.

An insole is provided that is constructed out of a mesh material that is stretched and suspended over a cavity formed in a shoe. The mesh surrounds a foam base and a rigid frame positioned under the foam base. The foam base is shaped so that a cavity is formed between the top surface of the foam base and the mesh positioned over the foam base to provide a “trampoline” effect for a wearer's foot.

An insole is provided that is constructed out of a mesh material that is stretched and suspended over a cavity formed in a shoe. The mesh surrounds a foam base and a rigid frame positioned under the foam base. The foam base is shaped so that a cavity is formed between the top surface of the foam base and the mesh positioned over the foam base to provide a “trampoline” effect for a wearer's foot.

A sockliner for a shoe or other article of footwear is formed having at least one generally flat, planar surface. At least a portion of the sockliner has a linear width that exceeds the linear distance across a width of the shoe. When the sockliner is placed in the shoe, pressure on the wider portions of the sockliner changes the conformation of the sockliner to conform to the shoe.

A sockliner for a shoe may be formed to include an integral fabric skirt. The fabric skirt may remain loose from the sockliner along at least a portion of the periphery of the sockliner. The loose periphery of the fabric skirt may be used to join the sockliner to other shoe components, as in a strobel-type seam.

An intelligent insole is provided. The intelligent insole includes an insole body, a pressure sensor, a temperature sensor, a humidity sensor and a signal collector. The pressure sensor, the temperature sensor and the humidity sensor are formed on the surface of the insole body, and the above sensors and the insole body are manufactured via the same 3D printing process. The pressure sensor senses the pressure signal from the insole body in contact with the foot. The temperature sensor and the humidity sensor respectively sense the temperature signal and the humidity signal of the insole body. The signal collector is respectively electrically connected to the pressure sensor, the temperature sensor and the humidity sensor to receive the pressure signal, the temperature signal and the humidity signal and then transmit the signals to a signal receiver via wireless transmission.

An intelligent insole is provided. The intelligent insole includes an insole body, a pressure sensor, a temperature sensor, a humidity sensor and a signal collector. The pressure sensor, the temperature sensor and the humidity sensor are formed on the surface of the insole body, and the above sensors and the insole body are manufactured via the same 3D printing process. The pressure sensor senses the pressure signal from the insole body in contact with the foot. The temperature sensor and the humidity sensor respectively sense the temperature signal and the humidity signal of the insole body. The signal collector is respectively electrically connected to the pressure sensor, the temperature sensor and the humidity sensor to receive the pressure signal, the temperature signal and the humidity signal and then transmit the signals to a signal receiver via wireless transmission.

Disclosed embodiments relate to a footwear system. The footwear system includes a shoe, a first insole, and a second insole. The first insole is a fitting insole having a first volume. It is positioned within the shoe during a fitting of a potential wearer of the shoe. The fitting insole is removed after the fitting is completed. The second insole has a volume substantially similar to the first volume. The second insole adapted for positioning within the shoe if the first insole demonstrates an appropriate fit. The second insole is self-customizable and further adapted to conform to the imprint of the sole of the potential wearer.

Disclosed embodiments relate to a footwear system. The footwear system includes a shoe, a first insole, and a second insole. The first insole is a fitting insole having a first volume. It is positioned within the shoe during a fitting of a potential wearer of the shoe. The fitting insole is removed after the fitting is completed. The second insole has a volume substantially similar to the first volume. The second insole adapted for positioning within the shoe if the first insole demonstrates an appropriate fit. The second insole is self-customizable and further adapted to conform to the imprint of the sole of the potential wearer.