A method of creating a cast of a foot comprises a stainless steel platform containing a layer of wadding (fig A). Foam is added to the wadding by mixing polyol and isocyante and pouring it into the platform (figs B-E). A thin protective layer of polymer is added to the surface of the foam and a layer of cushioning material is placed on top of the polymer (fig G). Once prepared the user places a foot onto the surface of the cushioning material (fig I), creating an impression of the underside of the foot in the foam. The foot is held in position for 2 ½ - 3 minutes for the foam to set. A custom made orthotic insert may be created using the cast.
