Custom Foot Orthotics

Custom foot orthotics can treat foot pain & more
Custom foot orthotics for plantar faciitis
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Massons specialises in the manufacture of precision custom made Foot Orthotics using CADCAM technology and are one of the market leaders in the manufacture of EVA foam-based foot orthotics. We are one of the few facilities that manufactures all our custom-made foot orthotics in-house and also fabricate for a number of centres in both Australia and New Zealand.


Foot Orthotics, commonly called "insoles", are specially designed shoe inserts to help stabilise, improve and correct poor foot posture. Your Clinical Orthotist will oversee your treatment from casting through to cast modifications, manufacture, fitting and review of the foot orthotics. 

We believe in a holistic approach to any bio-mechanical problem and understand that the underlying problem may not always be located around the area of the body that develops the symptoms. In some cases, the problem may be due to poor posture, pelvic mal alignment, leg length discrepancies, tight or poorly toned muscles for example.


Each foot is an engineering masterpiece made up of 26 bones, 33 joints and more than 100 muscles, tendons and ligaments. We tend to take this for granted until something goes wrong or we develop pain. Bio-mechanical problems affecting the feet can increase stresses within the foot structures and the surrounding soft tissues, creating localised pain in the foot, ankle and associated problems in the knees, hips and back.

Correction of poor foot biomechanics with Foot Orthotics can improve and prevent many types of symptoms such as:

  • Forefoot Pain (Metatarsalgia)
  • Arch Strain (Plantar Fasciitis)
  • Policeman’s Heel (Heel Spur)
  • Ankle Pain (Tibialis Dysfunction, Lateral Impingement Syndrome)
  • Shin Pain (Compartmental Syndrome, Shin Splints)
  • Knee Pain (Chondromalacia Patella, Patella Tibial Syndrome)

The aim of Foot Orthotics is to correct dysfunctional bio-mechanics which will:

  • Reduce pain
  • Provide support
  • Prevent or halt the development of foot deformity
  • Provide better positioning
  • Relieve pressure on a certain area of the foot
  • Improve the overall biomechanical function of the foot
  • Improve pelvic alignment
  • Reduce lower limb torsion and knee stress

We have classified our Foot Orthotics into different styles:

EVA Care

The CARE Custom EVA Insoles is designed for extra comfort and relief of foot pain. This insole can offload foot pressure and pressure peaks in combination with extra cushioning or medical diabetic application.   It has two ultra-soft EVA layers – a stabilising top layer with an extra cushioning bottom layer.

Insoles Massons Healthcare

EVA Comfort

The COMFORT Custom EVA insoles is designed for all day comfort, providing maximum efficiency and performance. The COMFORT orthosis is an all-round insole made from high quality dual medium density EVA consisting of a stabilising top layer with a comfort cushioning bottom layer.

EVA Performance

The PERFORMANCE Custom EVA insoles are a high-end, performance sport foot orthosis line designed for total control. Using a combination high quality tri-layer firm EVA, the insoles can transfer the power output rather than absorbing it. The Performance orthosis consists of a foot fixating top layer, a shock impact damping mid layer and a rigid bottom layer for control.

EVA Diabetic

The DIABETIC Custom EVA insole is designed to help absorb shock, deflect impact and reduce plantar pressures while supporting the structure of the foot.  It consists of materials of variable thickness and resistance to deformation to ensure the volume and depth of the insoles fit perfectly to the footwear.

EVA Dressed

The DRESSED custom EVA foot orthoses is designed to be worn everyday in dress shoes where there is inadequate space to put a full length insole. The DRESSED orthosis is made from high quality dual medium density EVA consisting of a stabilising top layer with a comfort cushioning bottom layer and helps to relieve the feeling of strain and restlessness from being on your feet all day.

Carbon Fibre and Polypropylene

Carbon fibre and polypropylene foot orthotics can be made upon request, however we generally recommend EVA technology which can be continually fine-tuned to adapt to your changing needs.

At Massons we understand that custom made orthotics are not for everyone and we have a great range of prefabricated, off the shelf foot orthotics available which can be fitted and adjusted by our staff if required.

Foot conditions treated with foot orthotics


Flat foot is a common and usually painless condition that occurs when the arches don't develop during childhood. In other cases, flat feet develop after an injury or from the simple wear-and-tear stresses of age.

The arch is referred to as the gap between the inner side of the foot and the ground. Flat foot or fallen arches is a condition in which the foot doesn't have a normal height arch and it may affect one foot or both feet.  

Fallen arches can cause problems such bunions, callus, corns, achilles tendonitis, shin pain, severe heel pain, knee and ankle pain.  It can sometimes contribute to problems in your ankles and knees because the condition can alter the alignment of your legs. If you aren't having pain, no treatment is usually necessary for flatfeet.

The primary cause of flat feet is over pronation which can be controlled with the use of insoles.  Most people have no signs or symptoms associated with flatfoot, but some people experience foot pain, particularly in the heel or arch area which may worsen with activity.  Swelling along the inside of the ankle can also occur.

Plantar Faciitis

Plantar fasciitis is an inflammation of the thick fibrous connective tissue (plantar fascia) at the bottom of your foot that runs from your heel to your toes. Characterised by stiffness and inflammation of the plantar fascia, it can also be associated with a bone spur on the heel. There may also be a partial or complete tear of the fascia.


Common signs and symptoms

  • Pain and tenderness on the sole of the foot usually localized at the heel bone with standing or walking
  • The pain is particularly noticeable with the first few steps after getting out of bed in the morning or after prolonged sitting
Plantar Faciitis


  • Inflexibility in the calf muscles
  • Flat (planus) or high (cavus) arched feet
  • Excessive foot pronation
  • Poor footwear
  • Repetitive micro trauma or stress to the heel tissues that may cause inflammation or calcification of the fascia of the foot
  • Irritation of the small nerve that runs under the foot where the fascia attached to the heel bone


  • Ice the affected area
  • Stretching
  • Custom foot orthoses and/or footwear prescription
  • Shockwave Therapy, Massage

Mortons Neuroma

Morton's neuroma is a painful condition affecting the ball of your foot most commonly between the third and fourth toes. Pain generally radiates towards the toes and intensifies with forefoot weight bearing and in shoes with insufficient forefoot width.  

Morton's neuroma involves a thickening of the tissue around one of the nerves leading to your toes which can cause a sharp, burning pain in the ball of your foot.  Your toes also may sting, burn or feel numb.

High-heeled shoes have been linked to the development of Morton's neuroma. Many people experience relief by switching to lower heeled shoes with wider toe boxes.

Mortons Neuroma


  • Localised tenderness between the 3rd and 4th (or 2nd and 3rd) metatarsals with pain that radiates down the involved toes
  • Aching and burning sensation
  • Highly sensitive to pressure either under the foot or from squeezing
  • Pins and needles (paraesthesia) in the toes
  • Increased pain and discomfort during forefoot weight bearing and in narrow fitting shoes


  • Swelling of the inter-digital nerve that is impinged by the metatarsals
  • Excessive pronation
  • Improper footwear, i.e. narrow fitting shoes or high heel shoes


  • Ice
  • Custom foot orthoses with metatarsal Domes and Bars
  • Appropriate shoe prescription
  • Possible cortisone injection


Shin splints are a painful strain on the front of the lower limb particularly when taking part in running or high impact activities and are the most common cause of exercise-induced leg pain encountered by athletes of all levels.  A shin splint is essentially an inflammatory reaction involving the deep tissues of the lower leg and may involve tendons and muscles, specifically the tibialis anterior muscle and tendon.

Excessive Pronation



The inflammatory reaction occurs at the point where the deep tissues insert into the inside (medial) or front (anterior) aspect of the leg bone (tibia).  Running and walking may be extremely painful and in severe cases, even light weight bearing may be painful.

The primary cause of shin pain is over pronation. Normal pronation, or "turning inward", of the foot is necessary as the foot adapts to the ground.  With excessive pronation, the arch flattens, collapses and soft tissues stretch. This causes the joint surfaces to function at unnatural angles to each other.

When this happens, joints that should be stable now become very loose and flexible.  Initially, excessive pronation may only cause fatigue but as the problem gets worse, strain on the muscles, tendons, and ligaments of the foot and lower leg can cause permanent problems and deformities.

Excessive Pronation

Symptoms can manifest in many different ways. The associated conditions depend on the individual lifestyle of each patient but may include any of the following:

  • Hallux Abducto Valgus or Bunions
  • Hallux Rigidus (stiff 1st toe)
  • Arch Pain
  • Heel Pain or Plantar Fasciitis
  • Metatarsalgia or ball of the foot pain
  • Ankle sprains
  • Shin Splints
  • Achilles Tendonitis
  • Osteochondrosis
  • Knee Pain
  • Corns & Calluses
  • Flat Feet
  • Hammer Toes

Top of Foot Pain

Top of the foot pain is a general term that is used by patients to describe pain in the top surface of the foot. It is common injury amongst runners and sporting people. A sharp pain on the top of my foot which is usually around the second metatarsal (in line with the second toe). Sometimes the pain can be localized around the 3rd or 4th metatarsal.

The two most common causes of this type of pain are either a stress fracture or tendentious of a metatarsal tendon. Athletes sometimes try and run through injuries such as heel pain, shin pain and achilles tendentious, which leads to this condition. Another cause of top of foot pain can be Extensor Tendonitis which can be more medially (more in line with the great and second toe). In severe cases, even light weight bearing may be painful. The primary cause of of this condition is over-pronation.

This can be controlled via insoles.


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