Creative Orthotic Design
Epione
orthotics
Introduction
At Epione, We specialise in the design
and fabrication of superior quality,
custom prescription foot orthoses.
We operate a state of the art
manufacturing lab that couples the
latest in computer aided technology
with the personal hand made care of
our skilled craftsmen. Ultimately this
ensures that we deliver precision
accurate, aesthetically pleasing orthotic
devices everytime.
Our philosophy is simple: to give our
customers exactly what they deserve. To us this means an extensive, yet fully
adaptable range of devices, a fast
turnaround time, a competitive pricing
structure and an excellent support
service.
Let Epione be your 1st choice for custom
prescription foot orthoses.
Contents
Design & manufacture protocol .............................................. 3
Functional Orthoses
Daily Functional / Daily Flex .................................................... 5
Dress Orthoses
Dress Standard / Cobra Dress .................................................. 7
Sport Orthoses:
Sportech / Sport Impact ................................................................. 9
Runner / Carbon Sport ................................................................. 10
Soccer / Golf .............................................................................................. 11
Sportysoft / Ski ...................................................................................... 12
Specialised Orthoses:
Diabe-tech / Control Max I ....................................................... 14
Control Max II / Control Max III ....................................... 15
Control Max IV ....................................................................................... 16
Shell Materials Matrix ..................................................................... 17
Shell Specifications ............................................................................ 18
Additions & Accommodations ............................................... 20
Contact & Policies ............................................................................... 24
2 • www.epioneorthotics.com
Design & Manufacture Protocol
Traditional or Digital Stream
Your 3-d scans/plaster molds/impression
foam boxes & completed prescription form
are sent to the labsporting activities.
Your 3/d scans/ plaster casts/foam boxes
are scanned into our cad software.
Your prescription variables are applied and
the resultant design is sent to our cnc
machine where a positive mold or direct
milled polypropylene orthotic is machined.
Direct Milled Orthotic
The direct milled device is then trimmed and
a finish grind is applied to the shell profile.
Vacuum Formed Orthotic
Extensions, additions and a top
cover is applied and the devices
is polished, labeled and quality
checked by our technician.
From the positive mold we then thermoform
the material of your choice over the positive,
trim and finish the shell profile. www.epioneorthotics.com • 3
Functional
4 • www.epioneorthotics.com
Functional
Daily Functional
Daily Flex
Our premium entry level orthotic, ideal for everyday activities and light
sporting activities.
Our entry level semi flex orthotic, for patients requiring only minimal
biomechanical control.
Lab Standard
• Semi rigid direct milled
polypropylene shell
• 14mm heel cup depth
• Functional shell grind
• Unitized extrinsic rearfoot post
• Black ultravinyl top cover
Lab Standard
• Semi flexible Direct milled
polypropylene shell
• 12mm Heel cup depth
• Functional Shell grind
• Unitized extrinsic rearfoot post
• Tan ultravinyl top cover
Applications
Most men and women’s casual,
walking, athletic, lace-up, and slip
on shoes with a deep heel counter
and adequate forefoot width.
Optional Shell Materials
• XT Sprint
Applications
Most men and women’s casual,
walking, athletic, lace-up and slip-on
shoes with a deep heel counter and
adequate forefoot width.
www.epioneorthotics.com • 5
Dress
6 • www.epioneorthotics.com
Dress
Specially designed for use with ladies and gents fashion / dress shoes
Dress Standard
Lab Standard
• Semi flexible Direct milled
polypropylene shell
• 10mm heel cup depth
• Dress shell grind
• Intrinsic rearfoot grind
• 3.2mm poron extension to sulcus
• Black ultrasuede top cover to sulcus
Dress Cobra
Applications
Suitable for dress shoes with a heel
height no greater than 1.5 inches in height.
Lab Standard
• Semi flexible Direct milled
polypropylene shell
• 8mm heel cup depth
• Cobra cut out shell design
• Intrinsic rearfoot grind
• Poron plantar arch fill
• 3mm black neolon top cover to sulcus
Applications
Suitable for fashionable high
heeled shoes.
www.epioneorthotics.com • 7
Sport
8 • www.epioneorthotics.com
Sport
High performance orthotics specifically designed for a variety of athletic applications
Sportech
Sport Impact
Designed for maximum shock absorption and functional control.
Lab Standard
• Semi-Rigid Direct milled
polypropylene Shell.
• 16mm heel cup depth
• Sport Shell width
• Unitized extrinsic rearfoot post
• Blue ultra vinyl top cover to mets
Indications
Most men and women’s athletic footwear.
Optional Shell Materials
• XT Sprint
Lab Standard
• Semi Flexible Direct milled
polypropylene shell
• 16mm heel cup depth
• Sport shell width
• Dual Density extrinsic rearfoot
post
• Low density eva plantar arch fill
• 1mm eva base layer
• 2mm Lunasoft top cover to toes
• White nylon grip plate
Indications
Most men and women’s athletic
footwear. Designed for high impact
sports where shock absorption is important.
www.epioneorthotics.com • 9
Sport
High performance orthotics specifically designed for a variety of athletic applications
Runner
Carbon Sport
Our running specific sport device with additional forefoot correction to
aid propulsion in the push-off phase.
Our gold standard lightweight, sport orthotic device.
Lab Standard
• Semi rigid direct milled
Polypropylene shell
• 16mm heel cup Depth
• Sport shell width
• High density EVA extrinsic
rearfoot Post
• Black nylon grip plate
• Extrinsic forefoot varus post to
sulcus (3 degrees)
• Neoprene top cover to toes
Lab Standard
• Semi Rigid vacuum formed TL
silver shell
• 14mm Heel cup depth
• Sport shell width
• High density EVA extrinsic
rearfoot post
• White nylon grip plate
• Silver ultra vinyl top cover to mets
Indications
Most men and women’s running shoes with sufficient heel cup & forefoot depth.
10 • www.epioneorthotics.com
Indications
Most men and women’s athletic
shoes. Narrower / slim fitting running shoes.
Sport
High performance orthotics specifically designed for a variety of athletic applications
Soccer
Golf
Designed specifically with the dynamics of golf in mind.
Lab Standard
• Semi Rigid Direct milled
polypropylene shell
• 10mm heel cup depth
• Reduced shell grind (narrow
midfoot cut)
• Narrow bevel extrinsic EVA
rearfoot post
• White Nylon grip plate
• Yellow/black marbel eva to sulcus
• Black ultra suede bottom cover
Application
For use in all football and rugby boots. Note: A template of the boot is required to
ensure a correct fit.
Optional Shell Materials
• XT Sprint
Lab Standard
• Semi flexible direct milled
polypropylene shell
• 12mm heel cup depth
• Sport shell grind
• Low density EVA plantar arch fill
• 1mm medium density eva base layer
• 3mm Neolon top cover to toes
Application
Designed specifically with the
dynamics of golf in mind. This device
will Gently control excessive frontal
plane rotation without blocking the
motions necessary during the swing
phase of the activity.
www.epioneorthotics.com • 11
Sport
High performance orthotics specifically designed for a variety of athletic applications
Sportysoft
Lab Standard
• Full length Direct milled medium
density EVA shell
• 16mm heel cup depth
• Sport shell grind
• 2mm blue/white EVA swirl pattern top cover.
Ski
Indications
For the sporting client when rigid
orthotic devices are poorly tolerated
or minimal biomechanical correction/
control is required. Available in met
length or full length.
12 • www.epioneorthotics.com
Lab Standard
• Semi rigid co-poly polypropylene
shell
• 12mm heel cup depth
• Ski shell grind (boot liner
required)
• Unitized extrinsic rearfoot post
• Poron forefoot extension to toes
• 1mm EVA top cover to toes.
• Black Vinyl bottom cover
Application
Modified functional shell style for
use in all alpine, nordic and
snowboard boots.
Note: The boots liner should be traced or
sent to ensure a good fit.
Specialist
www.epioneorthotics.com • 13
Specialised
Diabe-tech
Control Max I
Designed for the at risk, sensitive, neuropathic or diabetic foot.
UCBL design orthotic.
Lab Standard
• Low durometer direct milled
polyurethane shell
• Comfort shell grind
• Total contact anatomical shell profile
• Full length device
• 1.6mm Luminair top cover to toes
Lab Standard
• Direct milled polypropylene shell
• 25mm heel cup depth
• Medial and lateral flanges
• Wide shell profile
• Unitized Extrinsic rearfoot post
• 3mm Medium density EVA top
cover to toes.
Applications
Specificaly designed for the at-risk,
sensitive, diabetic or renopathic
foot. Very soft with total contact for
maximum pressure dispersion.
14 • www.epioneorthotics.com
Applications
Specially designed to offer maximum
STJ control for the excessive
pronator and paediatric / adultacquired flatfoot.
Specialised
Control Max II
Control Max III
Blake inverted device.
Lab Standard
• Direct milled polypropylene shell
• 22mm medial heel cup, 12mm
lateral heel cup height
• Unitized Extrinsic rearfoot post
• Unitized extrinsic forefoot post
• 5 degree Inverted shell profile (std)
• 4mm medial heel skive (std)
• 3mm medium density eva top cover
to toes
• Black nylon grip plate
Applications
Specially designed to offer maximum
STJ control for the excessive pronator
and paediatric / adult-acquired
flatfoot.
Lab Standard
• Semi rigid co-polymer
polypropylene shell (vacuum
pressed)
• 25mm medial heel cup, 12mm
lateral heel cup height
• High density extrinsic EVA oblique
hemi rearfoot post
• Blake inverted shell profile (std 25
degrees)
• 6mm medial heel skive
• 1mm eva shell cover
• 3mm medium density eva top
cover to toes
• Nylon grip plate
Applications
Specially designed to offer maximum
STJ control for the excessive
pronator and paediatric / adultacquired flatfoot.
www.epioneorthotics.com • 15
Specialised
Control Max IV
Laterally wedged orthotic device for the supinator.
Lab Standard
• Semi flexible direct milled
polypropylene shell
• 20mm lat heel cup depth, 12mm medial heel cup depth
• Unitized extrinsic rearfoot post
• 2mm Lat heel skive
• 2 degree valgus intrinsic forefoot
post
• 2 degree valgus forefoot post to sulcus.
• 3mm medium density eva top cover
to toes.
Applications
Lat deviated STJ axis/Peroneal
tendinitis/lat ankle instability.
16 • www.epioneorthotics.com
Shell Materials Matrix
Thermoplastics
Carboplastics
Impact Sport
Molds
Material
Thickness (mm)
180-220
220-270
Polypro
5mm
R
<80
R
R
R
S/R
Polypro
4mm
R
R
R
S/R
S/F
Polypro
3mm
R
R
S/R
S/F
F
Polypro
2mm
S/R
S/F
S/F
F
F
Copoly
5mm
R
R
S/R
S/F
F
Copoly
3mm
R
S/R
S/F
F
XT Sprint
3mm
R
R
R
R
S/R
XT Sprint
2.7mm
R
R
R
S/R
S/F
XT Sprint
2.3mm
R
R
S/R
S/F
F
XT Sprint
1.9mm
R
S/R
S/F
F
TL Silver
2.8mm
R
TL Silver
2.8mm
R
R
R
R
S/R
TL Silver 2.2mm
R
R
R
S/R
S/F
Polypro / Poron®
5mm
R
R
R
R
S/R
Polypro / Poron®
4mm
R
R
R
S/R
S/F
Polypro / Poron®
3mm
R
R
S/R
S/F
F
Polypro / Poron®
3mm
R
S/R
S/F
F
Polypro / Poron®
2mm
S/R
S/F
S/F
F
Polypro / Poron®
1.5mm
S/F
S/F
F
R = Rigid
80-120
120-180
S/R = Semi Rigid
S/F = Semi Flexible
F = Flexible
www.epioneorthotics.com • 17
Shell Specifications
Orthotic Width
PF Groove
Location / Characteristics
Wide (a)
• a) Shell to be 3-4mm wider than lab standard
Narrow (b)
• b) Shell to be 3-4mm narrower than lab standard
Location / Characteristics
• Groove incorporated into shell material in
area of medial plantar aponeurosis / flexor
hallucis brevis (as marked on casts)
Indications
• a) Excessive pronator to maximize contact
area with plantar surface area
• b) Slender / narrow foot-type, low profile footwear
Indications
• Anatomically tight plantar fascia
(especially if prominent with dorsiflexion
of 1st MPJ)
Deep Heel Cup
Lateral Flange
Location / Characteristics
• Heel cup depth greater than lab standard
for desired device: (range from
14mm-32mm)
• Device altered to deepen and subsequently
widen area of heel cup will widen entire
device slightly
Location / Characteristics
• Lateral border of device extended to
encompass more of the LLA
Indications
• Addition of skive to a device
• Optimization of rearfoot control
Indications
• Supinated foot type
• Chronic lateral ankle instability
Contraindications
• Dress footwear - deeper heel cup may
cause footwear fitting problems due to
added depth / width of device
Contraindications
• a) Low profile / narrow footwear
• b) Wide footwear deep heel cup (>14mm)
Contraindications
• Footwear which cannot accommodate
extra width needed for device
18 • www.epioneorthotics.com
Shell Specifications
1st Met Cutout
Navicular Aperture
Location / Characteristics
• Corner of shell material removed in area sub 1st MPJ
Location / Characteristics
• Depression / cavity in shell material
(in area as marked on cast), filled with Poron® contoured to surrounding
shell shape
Indications
• Dancers pad / FHL accommodation
• Plantarflexed 1st ray
Contraindications
• Hallux Rigidus
Indications
• Accessory navicular
• Bony exostosis
• Prominent navicular / cuneiform
1st Ray Cutout
Contraindications
• Desired sweet spot in area which will
not be in contact with the device
Location / Characteristics
• Corner of shell material removed in area
sub 1st Metatarsal, proximally extending
to base of 1st Metatarsal shaft.
Indications
• Functional Hallux Limitus
• Rigid Plantarflexed 1st ray • The addition of a FHL extension
Contraindications
• Hallux Rigidus
Medial Flange
Location / Characteristics
• Medial border of device extended to
encompass more of MLA
• Maximize control / contact area between
foot and device
Indications
• Excessively pronated foot type
• Medially deviated STJ axis
Contraindications
• Footwear which cannot accomodate extra
width needed for device
www.epioneorthotics.com • 19
Additions & Accommodations
Heel Cushion
Heel Aperture c Poron® Fill
Material / Characteristics
• 3mm Poron®
Material / Characteristics
• Cavity in shell material, filled with Poron® and contoured to shape of heel cup
Location
• Entire surface of heel cup, extending distally to level of anterior calcaneus
Indications
• Heel pain
• Heel spur
• Reduced fibro-fatty pad
Heel Raise
Material / Characteristics
• Firm EVA
Location
• Adhered to plantar surface of extrinsic
rearfoot post
Indications
• Leg length discrepancies (unilaterally)
• Achilles tendinitis (use bilaterally)
20 • www.epioneorthotics.com
Location
• Medial calcaneal tubercle
Indications
• Heel spur
• Plantar Aponeurosis insertional pain
Contraindications
• No intrinsic rearfoot stabiliser (excluding molds, sport impact devices
Additions & Accommodations
Met Bar
Met Dome
Material / Characteristics
• Prefabricated Poron® pad (small, med,
large sizes-based on foot size)
Material / Characteristics
• Prefabricated Poron® pad (tear-drop
shaped) small, med, large size - based on
foot size)
Location
• Centered on 2-4 Metatarsals extending
3-4mm beyond distal edge of device
Indications
• Metatarsalgia
• Forefoot callusing
Rigid Shaft Extension
Material / Characteristics
• Extension of shell material sub 1st
Metatarsal-Phalangeal joint
• Polypropylene only
Location
• Centered on 3rd Metatarsal, extending
3-4mm beyond distal edge of device
Indications
• Metatarsalgia
• Dropped lesser Metatarsal
• Forefoot callusing
• Interdigital neuroma
• Intermetatarsal-phalangeal bursitis
Contraindications
• Rigid / immobile forefoot
Location
• Continuation of shell material to end of
1st digit
Indications
• Hallux Limitus / Rigidus
• Short 1st Metatarsal with Hallux Limitus or pain on dorsiflexion
• Turf toe
Contraindications
• Normal 1st MPJ ROM (will act as a splint /
facilitate low gear toe-off)
www.epioneorthotics.com • 21
Additions & Accommodations
Reverse Mortons Extension
Material / Characteristics
• 3mm Cushion Cork
Location
• Applied to distal / dorsal aspect of shell to level of sulcus 2-5 MPJ (no cork sub 1st MPJ)
Indications
• Plantar-flexed 1st ray
• Low gear push off
• Forefoot Valgus
Contraindications
• Hallux Limitus / Rigidus
• O/A with Osteophytic Lipping
Mortons Extensions
Material / Characteristics
• 3mm cushion cork
Location
• Sub 1st Metatarsal - phalangeal joint
extended from distal end of shell to sulcus
Indications
• Short 1st Metatarsal in relation to length of 4th / 5th Metatarsals
• Dorsiflexed 1st Ray
• Hallux Limitus (mild)
Contraindications
• Long 2nd Metatarsal in relation to Metatarsal
22 • www.epioneorthotics.com
Functional Hallux Limitus
Accommodation
Material / Characteristics
• 3mm EVA
Location
• Applied from distal / plantar aspect of shell to sulcus, square-shaped cut out to
1st MPJ (*1st Met cutout in shell
automatically performed with this addition)
Indications
• Functional Hallus Limitus
Contraindications
• Anatomical Hallux Rigidus / Limitus 1st
MPJ O/A with osteophytic lipping
Additions & Accommodations
Forefoot / MPJ Lesion
Accommodation
Material / Characteristics
• 3mm cushion cork extension (or Poron®)
Location
• Forefoot extension tapered onto
distaldorsal aspect of shell extending to
level of sulcus (1-5) with cutout to lesion
site (as marked on negative cast)
Indications
• Persistant / painful corn, callus or plantar warts / ulceration
• Dropped Metatarsal-phalangeal joint
• MTPS Capsulitis
Contraindications
• Will add extra thickness in forefoot area,
therefore not recommended unless
footwear can accommodate adequately
Dancer’s Pad
Material / Characteristics
• 3mm cushion cork extension to sulcus
Location
• Forefoot extension started at the base of
the Metatarsal, extending to level of
sulcus with a cutout to the 1st MPJ (*1st
Met cutout in shell automatically
performed with this addition)
Indications
• Rigid, severely plantarflexed 1st ray
• Sesamoiditis
• Fractured Sesamoiditis
• Contused Sesamoiditis
Contraindications
• Hallux Limitus / Rigidus
• 1st MPJ O/A
www.epioneorthotics.com • 23
Policies
Product Guarantees
Production Time
• Polypropylene, coplymer and carboplastic shells are guaranteed
against breakage for the functional life of the device
• Soft mould devices are guaranteed against excessive compression for 6 months
• Top covers, additions and extensions cannot be guaranteed as
individual body chemistry, weight and activity levels can cause wear
at varying rates
We guarantee that all orders will be fabricated and shipped within 10 working days from receipt of order.
5 working day rush service is available at an additional cost.
Order will be shipped 5 days from receipt of casts/scans.
Second Pair Orders
Adjustments
Minor adjustments to your original prescription for fit, function or
comfort will be made AT NO CHARGE within 6 months from date of
shipping. Charges will apply for new components / additions or major
changes to your original prescription.
Returns
Custom orthotics are not returnable for credit as each device is
fabricated from your mould / impression and your prescription. We can
not be held responsible for error on your behalf. We will however work
with you to attempt to resolve your orthotic problems.
Epione Orthotics
Rush Orders
Second or subsequent pair orders will receive a 10% discount.
Cast Storage Negative
Scanned negative impressions and digital corrections are stored for 5 years.
Credit Card Payment
We offer our customers the option of paying invoices with visa,
mastercard or debit cards. Payment terms are net 14 days from invoice issue date.
10a Albert Street Aberdeen AB25 1XQ
t: 01224 561999 e:[email protected] - General Enquiries
e:[email protected] - Customer Support
www.epioneorthotics.com
VAT Registration No. 928 9957 47
Company Registration No. 296949