Refurbishing Cracked Foot Orthotics Tutorial

Custom foot orthotics are vital for supporting your feet, but cracks in the shell can reduce their effectiveness. While refurbishing cracked foot orthotics tutorial guides are often sought for DIY solutions, this process is complex and typically requires professional intervention due to the specialized materials involved.

Cracks in the rigid shell—often made of plastic or carbon fiber—indicate structural damage that affects the orthotic’s ability to support your feet. Attempting a DIY fix with adhesives like epoxy might temporarily hold the crack, but it won’t restore the shell’s integrity, potentially leading to discomfort or further foot issues. Instead, professionals can fully refurbish cracked orthotics by replacing the damaged shell. The process involves stripping the orthotic down to its base, replacing the shell with a new one, and adding fresh padding and top covers. Companies like OrthoRestore emphasize that if the plastic shell is cracked, a duplicate orthotic may be necessary, as simple repairs won’t suffice.

For minor cracks, you might clean the orthotic with mild soap and water, apply a thin layer of epoxy to the crack, and let it cure for 24 hours. However, this is a temporary fix and not recommended for long-term use. Professional services, which can take 3-5 business days including shipping, ensure the orthotic is restored to its original functionality. They also replace worn padding and covers, addressing all aspects of wear.

If your orthotics are cracked, consult a podiatrist to assess whether refurbishment or replacement is best. While DIY methods can be a stopgap, professional refurbishment is the most reliable way to ensure your orthotics continue to support your feet effectively.

Where to Send Foot Orthotics for Refurbishing

When your foot orthotics wear out, refurbishing them can extend their life at a fraction of the cost of new ones. Knowing where to send foot orthotics for refurbishing ensures you choose a reliable service to restore their functionality.

Several reputable companies specialize in orthotic refurbishment. Orthotic Repair Services (ORS) offers a comprehensive service, stripping orthotics down to the shell and replacing all components, including padding and top covers. They provide a prepaid shipping label, and the process typically takes a couple of weeks, with customers praising their quality and customer service. Legendary Orthofix also provides refurbishment, restoring orthotics to a like-new condition with new materials, requiring you to email them upon sending your orthotics for priority processing. 

ORS is another option, with a quick turnaround of 1-2 business days for refurbishment once received, and 5-7 days for duplication. Foot Dynamics also services orthotics from various manufacturers, though not all devices are refurbishable—those with plastic shells are typically eligible.

To send your orthotics, check the provider’s website for an order form, follow their shipping instructions, and include any specific requests for materials or padding. Always consult a podiatrist if you’re experiencing pain, as they can guide you on whether refurbishment is appropriate for your condition.

Refurbishing Foot Orthotics with New Padding

Over time, the padding in foot orthotics can compress, reducing comfort and support. Refurbishing foot orthotics with new padding can restore their cushioning, making them feel like new again.

Padding, often made of foam or polyurethane, absorbs daily wear but eventually “bottoms out,” as noted by Newman's Shoe Repair. For a DIY approach, you can replace the padding yourself. Start by cleaning the orthotic with mild soap and water, then remove the old top cover and padding using a utility knife to peel them away carefully. Cut new foam padding—available at craft stores—to match the orthotic’s shape, slightly larger than needed. Apply a strong adhesive like shoe goo to both the orthotic shell and the foam, let it become tacky, then press the new padding on, ensuring it’s smooth. Trim excess material and let it cure for several hours.

Professionally, services like ORS and SOLO Labs strip the orthotic to its shell, clean it, and add new padding along with a new top cover. This ensures even cushioning and proper alignment, which is crucial for maintaining the orthotic’s therapeutic benefits. The process typically takes 3-5 business days, including shipping.

Adding new padding can significantly improve comfort, but if the shell is damaged, professional refurbishment is necessary. Regular maintenance, like cleaning and checking for wear, can help prolong the life of your orthotics’ padding.

Can You Refurbish Soft Foot Orthotics

Soft foot orthotics, often used for conditions like diabetes-related foot issues, provide cushioning but wear out over time. A common question is, can you refurbish soft foot orthotics, and the answer depends on their condition and material.

Soft orthotics, made of flexible materials like foam or gel, are categorized as “accommodative” orthotics. According to Orthoticrepairs.com, these are more prone to damage during refurbishment compared to functional orthotics with hard plastic shells. If the soft material has compressed or torn, refurbishing can be challenging because the entire device may need replacement. However, if the wear is limited to the top cover, refurbishment is possible by replacing the cover with new foam or fabric.

For a DIY approach, clean the orthotic, remove the old cover, and attach a new foam layer with adhesive. However, this may not restore the orthotic’s full support, as the base material might be too worn. Professional services like SoleScience can refurbish soft orthotics if the supportive components are intact, often replacing the cushioning and cover to restore comfort. They note that soft materials wear out faster, typically lasting 1-2 years.

If the soft orthotic is severely degraded, replacement might be more practical, as noted by Upstep, which suggests new orthotics after 12-18 months of use. Consult a podiatrist to determine if refurbishment is viable for your specific soft orthotics.

Refurbishing Foot Orthotics for Flat Feet

Flat feet can cause pain and alignment issues, and custom orthotics are often prescribed to provide arch support. Refurbishing foot orthotics for flat feet ensures they continue to offer the necessary support as they wear out over time.

Worn orthotics may fail to support the arch, leading to increased discomfort. Signs of wear include compressed padding, torn covers, or a distorted shell, as highlighted by Wisconsin Foot Center. For minor wear, a DIY approach involves cleaning the orthotic, removing the old top cover, and attaching a new foam cover with adhesive to restore cushioning. However, flat feet require precise arch support, so professional refurbishment is often better. Services like ORS and Legendary Orthofix strip the orthotic to its shell, replace all components, and ensure the arch support is intact, which is critical for flat feet.

OrthoRestore notes that orthotics for flat feet often have specific features like arch supports and heel pads, which they can replicate during refurbishment. This process ensures the orthotic continues to correct overpronation, a common issue with flat feet, as mentioned by HSS. Refurbishment can take 3-5 business days professionally, while DIY might take a day.

Always consult a podiatrist to ensure the refurbished orthotics meet your needs, especially since flat feet can lead to other issues like knee or back pain if not properly supported.

How to Clean and Refurbish Foot Orthotics

Maintaining foot orthotics through cleaning and refurbishment can extend their lifespan and keep them comfortable. Knowing how to clean and refurbish foot orthotics ensures they remain effective for daily use.

Cleaning: Start by removing the orthotics from your shoes. Use a mild soap and lukewarm water with a soft cloth to gently clean the surface, removing dirt and sweat. Avoid soaking them, as excessive water can damage the materials, especially if they have foam padding. Dry them completely with a towel and let them air dry away from direct heat, which can warp the shell.

Refurbishing: For minor wear, focus on the top cover. 

• Peel off the old cover if it’s loose, clean the shell of any adhesive residue with a mild solvent (if safe for the material), and cut a new foam or leather cover to size. 
• Apply a strong adhesive like shoe goo, attach the new cover, and let it cure for several hours. Trim excess material for a neat finish. 
• For deeper refurbishment, like replacing padding, professional services are recommended, as they can address all components, including the shell, as noted by SOLO Labs.

Regular cleaning prevents material breakdown, and refurbishing can restore comfort, but consult a podiatrist if you notice persistent discomfort after the process.

Refurbishing Foot Orthotics for Kids Shoes

Children’s foot orthotics, often prescribed for conditions like flat feet or overpronation, can wear out quickly due to active use. Refurbishing foot orthotics for kids shoes can save money and ensure continued support for growing feet.

Kids’ orthotics typically have softer materials to accommodate growth, but these wear out faster, as noted by SoleScience, lasting about 1-2 years. For minor wear, a DIY approach involves cleaning the orthotic with mild soap and water, removing the old top cover, and attaching a new foam cover with adhesive. This can restore comfort for daily use in kids’ shoes. However, children’s feet change rapidly, so professional refurbishment might be necessary to adjust the fit. Services like SOLO labs can replace all components, ensuring the orthotic still supports the child’s foot shape.

HSS notes that orthotics for children often address deformities, so it’s crucial to maintain their effectiveness. Professional refurbishment, which takes 3-5 business days, ensures the orthotic adapts to the child’s growth. 

Always consult a podiatrist to assess if the refurbished orthotic still meets the child’s needs, as improper support can affect development.

Best Materials for Refurbishing Foot Orthotics

Choosing the right materials is crucial for effective refurbishment of foot orthotics. The best materials for refurbishing foot orthotics ensure durability, comfort, and proper support.

Top Covers: Foam, neoprene, or vinyl are popular choices. Legendary Orthofix offers options like 1/8” neoprene (similar to Spenco) or 1/16” to 1/4” foam with vinyl, providing comfort and durability. Leather is another option for a premium feel, as used by Newman's Shoe Repair.

Padding: Polyurethane or soft foam is ideal for cushioning, as noted by 

OrthoRestore, which uses these to replace worn padding. These materials absorb shock and provide comfort without adding bulk.

Adhesive: A strong, flexible adhesive like shoe goo is essential for DIY refurbishment, ensuring the new cover and padding adhere well to the shell.

Shell (if replacing): For cracked shells, professionals use plastic or carbon fiber, as mentioned by Orthoticrepairs.biz, to maintain structural integrity. These materials are robust and long-lasting.

Using high-quality materials ensures the orthotic remains supportive and comfortable. For DIY, source materials from craft stores, but for complex repairs, professional services can provide premium materials tailored to your orthotic’s needs.