The prescription and manufacture of personalised bespoke orthotics aim to correct and prevent Symptoms related to a number of conditions concerning poor gait, Current fabrication methods involve modular designs built upon prefabricated components. This paper reviews classifications for orthotics and materials for their manufacture depending on whether they are rigid, semi rigid or soft. Manufacturing methods for the production of rigid customised carbon fibre orthoses are described. Epoxy pre-impregnated carbon fibre material was laid up onto a positive mould of a subject's foot to achieve an accurate geometrical relationship between the plantar surface of the foot and the insole. Manufacturing techniques including vacuum bagging and autoclaving were used to produce a thin profile, allowing the device to be placed in footwear where space is at a premium. The final results were observed to meet the requirements of the subject, providing comfortable and supportive rigid orthoses.
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