An orthotic device for use with an individuals footwear is customised to the individuals therapeutic, comfort and footwear requirements by using, as a template for its manufacture, an existing orthotic device that has been previously created for that individual. The therapeutically contoured shape of the existing device is captured in a malleable layer that sets to be self-supporting, so to allow creation of a new therapeutic layer that replicates the surface of the existing device and that forms a therapeutic surface of the new device.
