Nipissing Orthopaedic Laboratory Inc.

A leading provider of prosthetic and orthotic devices, custom made foot orthotics, and specialty footwear to the people of Northeastern Ontario since 1990, now in our 25th year

25th Anniversary

The Process

During the course of your treatment process, a history of the ailment from which you suffer will be taken and appropriate testing of your physical abilities and limitations will be evaluated. In some cases this testing is more elaborate and in other cases less so. From this consultation and evaluation process, a specific orthotic or prosthetic treatment protocol will be developed for you.

Shown are photos taken during a recent casting for a client with severe ankle arthritis.

Not all devices require a casting as demonstrated below, but the process shown is quite typical for many. The same general concept applies for all custom made devices including spinal and upper extremities or for prosthetic sockets.


1) Start of clinical assessment, digital imprint, casting of involved body segment, history of injury or ailment, and often discussion with other health professionals.


cast inspection

2) In this case a Plaster of Paris cast is taken to capture optimal foot position. Here the foot cast is deemed acceptable and next steps in casting can take place.

cast reapplied

3) The foot cast is an integral part of the device and becomes the base for the device.

lower leg wrapped

4) Prior to removal, optimal limb alignment is maintained while cast sets.

cast removed

5) The cast is removed in a special process.

manufacture cast

6) The involved lower leg segment is captured within this cast and the device construction can now commence.

plaster of paris cast

7) Close-up of this client’s unique foot shape and alignment captured with the plaster of Paris hand casting technique.

prepare lower leg

8) Examination of bony prominences and landmarks during casting.