The Process

It Begins With The “Last”

Making sure each shoe is treated with care and precision from the template stage until they reach the patient’s feet. CAD/CAM technologies provide an accurate method to record the anatomical structure and create a custom fit to serve your orthopedic needs. The shoe undergoes more than 25 separate construction steps and quality approval checks before it is shipped to you.

1. FITTING THE FOOT
2. SCAN & MODIFY
3. PATTERN ENGINEERING
4. PRECISION CUTTING
5. HANDCRAFTED ASSEMBLY
The “last” is an exact replica of the patient’s foot.
A professional craftsman prepares the negative cast.

FITTING THE FOOT

Tru-Mold shoes fit perfectly because they are made from an exact replica of the foot. Every external anatomical detail is revealed on this three-dimensional plaster “last” of the foot, molded by a healthcare professional. The cast not only reveals a patient’s precise foot length and width, but all profiles such as bony prominences, pressure points, sensitive areas and other conditions unique to the foot. From this we are able to make a shoe and a total contact insert which accommodates every contour and bio-mechanical feature of the foot.

Scan and modify
A scanner creates a real-time 3D image.
A professional technician makes necessary modifications.

SCAN & MODIFY

A scanner creates a real-time 3D image and design software is used to extensively customize the positive cast. 250,000 measurements are scanned to ensure highest anatomical accuracy to reproduce every outline of the foot. Scans are stored in our database indefinitely for future reference. If a patient’s condition should change in any way, modifications can be made quickly and efficiently. We can refer to the original last measurements and make changes accordingly to produce a new shoe that accommodates the patient’s new condition. Production-ready scans for all types of shoes, braces, and inserts can be created in less than a minute.

Pattern engineering software is used to design the upper component of the shoe.
Patterns are graded and designed to meet individual’s specific needs.

PATTERN ENGINEERING

Advanced pattern engineering and grading software is used to design the upper of the shoe. Complex manual processes are emulated in a fraction of the time with a level of accuracy that is only possible with a computer based system. Although custom-molded shoes may look different than conventional shoes due to their unique modifications, we make every effort to ensure that your footwear appears cosmetically pleasing without compromising your needs for precise fit, comfort and function.

A high-speed precision cutter carves out textiles.
Tru-Mold shoes are constructed using some of the most durable and lightweight materials available.

PRECISION CUTTING

High speed precision cutter carves out textiles and leather for the final production of the shoe. It is equipped with a “pinch and grab” feeding system that assures highest feeding accuracy and maximum material fixing. Tru-Mold shoes are constructed using some of the most durable and lightweight materials available today, including glove leather uppers and lining, customizable bases, Plastazote inserts and abrasive-resistant soles.

Our talented and experienced craftsmen meticulously hand assemble each shoe.
Each finished product is created with great attention to detail.

HANDCRAFTED ASSEMBLY

Custom-molded shoes are made with special measurements to accommodate the unique conditions of your feet. These modifications can alter the shape and appearance of the custom footwear. Through handcrafted assembly, a skilled craftsman has full control over the final process to ensure the shoe remains fashionable and therapeutically correct.