Manufacturing Interdigital Silicone Orthoses Using Podiatry Putty

Practical Guide for Podiatrists

Interdigital silicone orthoses play a vital role in podiatric practice, providing targeted relief for conditions such as hammertoes, bunions and interdigital corns. These custom-made devices are designed to realign toes, relieve pressure and prevent further deformity—improving both comfort and function for patients. This guide outlines the materials, techniques and best practices for producing interdigital silicone orthoses using podiatry-grade mouldable putty.

What Are Interdigital Silicone Orthoses?

Interdigital silicone orthoses are small, custom-moulded devices that fit comfortably between the toes. They provide cushioning, help correct alignment and redistribute pressure to relieve pain and friction. Mouldable silicones are preferred for their flexibility, durability and easy adaptability during clinical fabrication.

Materials Required

• Mouldable Silicone Putty: Common options include Otoform KC and Fresco Silicone Putty.
• Catalyst Hardening Paste: Ensures proper curing and the desired firmness.
• Measuring Tools: Spoons or small digital scales for precise proportioning.
• Mixing Equipment: Bowls and spatulas for thorough blending of materials.
• Modelling Tools: Spatulas, shaping instruments or simple moulds for detailed contouring.

Step-by-Step Manufacturing Process

1. Clinical Assessment and Measurement
   Begin with a detailed assessment of the patient’s condition. Identify sites of friction, pain or deformity, and measure the interdigital space to determine the size and contour required.
2. Preparing the Material
   Combine the silicone putty with the catalyst according to the manufacturer’s instructions. Mix until the material reaches a uniform, pliable texture—firm enough to maintain shape yet soft enough for manipulation.
3. Moulding and Shaping
   Shape the silicone into the desired configuration using modelling tools, either directly on the patient’s foot (with appropriate barrier/skin protection) or on a model. Adjust for comfort, alignment and effective pressure redistribution.
4. Curing and Finishing
   Allow the silicone to cure fully—typically several hours or overnight depending on the product. Once set, inspect carefully, smoothing any rough edges and refining contours for optimal comfort and function.
5. Fitting and Patient Education
   Fit the finished orthosis to ensure comfort and stability between the toes. Provide clear instructions on daily use, cleaning procedures and signs of wear or material fatigue that would warrant review or replacement.

Best Practice Tips for Podiatrists

• Prioritise Comfort: Ensure the device does not cause rubbing, maceration or excessive pressure.
• Choose Quality Materials: High-quality silicones and catalysts provide consistent elasticity and longer service life.
• Review Early and Often: Schedule follow-ups—especially within the first few weeks—to evaluate function, fit and patient adherence.
• Maintain Competence: Stay current with advances in silicone formulations, infection control and orthotic design to enhance outcomes.

Clinical note: Always follow manufacturer directions for mixing ratios, curing times and contraindications. Consider protective dressings or skin barriers when moulding directly on the foot, and document patient consent and aftercare advice.