Replacing Top-Covers of Custom Orthotics / Arch Supports

After a year or more of wearing custom orthotics, the top-covers can start to become worn. This can be unsightly and uncomfortable. However, instead of purchasing entirely new custom orthotics, there is a much more economical way to restore your current orthotics to a "like-new" condition! Replacing the worn top-covers is just one step in this restoration process.

*Replacing top covers requires special materials, glues, and tools that can make the process costly and difficult for a DIY project. Let us replace your top covers for you! Visit our products/services page for orthotic repair options.

How to Replace Top-Covers of Custom Orthotics / Arch Supports:

Step 1: Assessment (How damaged is your orthotic?)

It's a good idea to first assess the type of orthotic you have; to ensure it is worth recovering. It must be possible to recover without damaging the supportive aspects of the orthotic "shell or arch". There are thousands of different orthotic designs, using many different materials. To simplify things for this article, we will separate them into 2 categories: "Functional" (a harder plastic/carbon fiber on the bottom/arch) and "Accomodative" (softer, more pliable material on the bottom/arch). As a general rule, functional orthotics are more acceptable to work with, while some of the accomodative ones can be more easily damaged during the process.

*We will be happy to assess your orthotics for you! Simply text a picture of your current orthotic to (864) 506-0453 or email a picture to orthoticprepairs.com@gmail.com

Step 2: Top-Cover Removal

After determining the orthotic can be recovered, we can start the removal process. In some cases, the covering can be peeled or pulled off. However, it's important to make sure secondary layers are not being damaged during this process. (Which is why we do not recommend attempting this at home.) When the covers cannot be easily peeled off, a soaking solutions is needed. We typically use an industrial thinner, applied carefully and evenly across the orthotic top covers. Again, this is best left to an experienced professional, as too much can cause unintended damage to the orthotic. We then soak for approx. 15 min. in a covered container for proper, even absorption. At this point the glue/cement will be released and the covers should be able to be removed. Sometimes we use a small dremmel or grinder to remove the stubborn portions. The same method can be used for removing material on the bottom if needed.

Step 3: Cleaning the shells

In most cases, it is recommended to clean the shell of excess glue or other material in order to ensure the new covers hold well. Using the same thinner and a metal scraper or grinder can accomplish this quite effectively.

Step 4: Applying new covers and bottom material

We typically use a template (either an insole from your shoe or the old orthotic) during this step to help get the proper length and width of the orthotic. Material should be cut larger than needed to ensure room for the heel, arch, and other areas of the orthotic to adhere properly while having enough extra material to cut the forefoot. First, a thin layer of industrial shoe cement is painted on. We make sure to cover the orthotic shell completely as well as the bottom portion of the top covers. Next, we use a heat gun to fully process the cement. Once the glue is the proper consistency, it is time to put on the covers. We firmly adhere both the top and bottom covers, using a careful process to ensure they are completely smooth and evenly adhered. Once this is accomplished we use the template to cut to the appropriate length and width. We use a grinder at this point to smooth out all the edges and give the orthotics a nice, clean look.

We can repair your current orthotics and make them like-new for a fraction of the cost! For questions or repairs, please call us at (864) 506-0453, email us, or visit our SHOP/PRODUCTS page to browse various repair options.