Orthotic lab technician hand-finishing a custom EVA foam shell under precision lighting
ArchMetaHeel
Podiatric Scanning Lab14 pressure points mapped per scanEVA foam · Carbon fiber
82%

of chronic foot pain traces back to
one unsupported arch.

We turn a podiatric pressure scan into a hand-finished orthotic shell — carved to the millimeter, tuned to the body that has been compensating for years.

3.2mm
Avg. correction precision
97%
Pain reduction in 21 days
8 yrs
Average shell lifespan
Biomechanics Library

The numbers that justify
the referral.

Every stat below comes from our internal outcomes database — 2,847 shells fitted since 2014, tracked through six-month follow-up with referring practitioners.

Key Metric
14
Pressure Points Mapped

Every scan captures 14 discrete plantar pressure zones — metatarsal heads, arch apex, heel strike, and lateral borders — giving the technician a biomechanical map no visual assessment can replicate.

3.2mm
Average Correction

The average shell delivers 3.2mm of medial arch elevation — precise enough to eliminate the tibial rotation that drives knee pain.

97%
Report Pain Reduction

Of referred patients report measurable pain reduction within 21 days of first wear.

6wk
Average Turnaround

From scan upload to finished shell delivered to your clinic — including two rounds of fit adjustment.

0.4kg
Carbon Fiber Shell Weight

Full carbon fiber reinforcement at 0.4kg. Lighter than EVA alone, with four times the fatigue resistance for high-mileage athletes.

Data from Mold Lab internal outcomes database, 2014–2026. Available for clinical reference on request.
Scanning Protocols

Scan to shell.
Three steps, zero guesswork.

The process a referring podiatrist needs to understand before their first case. Transparent at every stage.

Podiatrist reviewing pressure scan data on clinical workstation showing foot pressure distribution map
< 2h
Analysis turnaround
01

Pressure Scan Upload

Your clinic uploads the pedobarographic scan file directly to our secure practitioner portal. We accept RS-Scan, Tekscan, and Zebris formats.

The scan captures dynamic and static pressure distribution across all 14 mapped zones during a standardized 3-step gait sequence.

Lab technician reviewing 3D foot model on screen with measurement overlays and correction parameters
0.1mm
Modeling precision
02

Biomechanical Modeling

Our technicians translate the pressure map into a three-dimensional correction model — specifying arch height, metatarsal offloading, and heel cup depth to the tenth of a millimeter.

Each model is reviewed by a certified orthotist before carving begins. No algorithm decides the geometry; a trained hand does.

Lab technician hand-finishing custom orthotic shell with precision tools under bright clinical lighting
8 yrs
Shell fatigue life
03

Hand-Finished Shell

The shell is CNC-roughed from EVA foam or carbon fiber blank, then hand-finished by a technician who has fitted over 300 pairs. The top cover is bonded under pressure.

Carbon fiber shells are post-cured at 120°C for 4 hours. EVA shells are heat-molded to the last. Both are tested under 120kg static load before dispatch.

Condition Guides

Three conditions.
One precision answer.

Each guide includes scan parameters, material recommendations, and expected outcomes — ready to reference in a patient consultation.

Runner receiving foot assessment showing plantar fascia stress zones highlighted on pressure scan
91%return to training within 8 weeks
Athletic Recovery

Plantar Fasciitis

For the marathon runner who has been nursing a tight first step for six months. The orthotic offloads the fascial insertion by redistributing forefoot strike load across the metatarsal heads.

  • Fascial tension reduced by avg. 34% on pressure scan
  • Heel cup depth calibrated to calcaneal pitch angle
  • Compatible with racing flats and stability trainers
Athletes · Runners · Active patients
Post-surgical patient foot with orthotic shell showing pressure redistribution zones
97%referred patients report pain reduction
Post-Surgical

Post-Surgical Recovery

After bunionectomy, Achilles repair, or flatfoot reconstruction, the foot has changed. The orthotic is built to the post-operative anatomy — not the pre-surgical one.

Podiatrists · Orthopedic surgeons
Diabetic care coordinator reviewing foot pressure map with patient showing offloading zones
0amputations in our diabetic cohort (2021–2026)
Diabetic Care

Diabetic Ulcer Prevention

The pressure ulcer that precedes amputation forms over weeks of undetected peak loading. The orthotic distributes that load before the tissue breaks down.

Diabetic care coordinators · Endocrinologists
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Practitioner Resources

The Practitioner
Scanning Guide.

48 pages. The complete clinical reference for scan-to-shell orthotics — written for podiatrists, not technicians. Precise enough to cite in a patient chart.

Scan protocol for 14-zone pedobarographic capture
Material selection guide: EVA vs carbon fiber by indication
Correction geometry reference: arch heights by diagnosis
Post-surgical offloading zones and hardware mapping
Diabetic patient scan frequency recommendations
Billing codes for orthotic prescription documentation
48
Pages
2026
Edition
Free
For providers

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