Custom orthopedic soles for footwear are not just another component of the shoe: they are a technical element that directly affects posture, comfort and walking quality. In orthopedic footwear, every detail has a concrete impact on the wearer’s everyday wellbeing, and the sole is the key interface between foot, insole and ground.
For this reason, PBS Soles works alongside footwear manufacturers, brands and orthopedic technicians in the design and production of customized orthopedic soles, engineered to meet specific functional requirements, even complex ones.
Why custom orthopedic soles make the difference
A standard sole, designed for generic footwear, cannot guarantee the level of precision required in the orthopedic field. Custom orthopedic soles for footwear must:
- correctly support the plantar arch;
- help realign posture when necessary;
- improve load distribution while walking;
- reduce pain and fatigue in the presence of pathologies or foot issues.
The sole thus becomes an integral part of the orthopedic project: it not only supports the foot, but works in synergy with insoles, contoured footbeds and the upper to accompany each step in a more stable and comfortable way.
Materials for orthopedic soles: microporous, EVA and technical rubber
Material selection is one of the most important aspects in the production of custom orthopedic soles for footwear. PBS Soles mainly works with:
- Microporous material
A lightweight material with good shock-absorbing properties and a structure that combines support and comfort. It is particularly suitable for orthopedic and comfort footwear because it provides a stable base without being excessively rigid. - EVA (Ethylene Vinyl Acetate)
Ideal when an elastic, cushioning sole with low weight is required. EVA is a good choice for projects that demand a soft response at foot strike while maintaining sufficient durability. - Technical rubber
Used especially in high-wear areas or as an outsole, it provides grip, resistance and safety. Combined with microporous material or EVA, technical rubber allows orthopedic soles with excellent traction and long-lasting performance.
By combining these materials, it is possible to finely calibrate the behavior of the sole according to project needs: more support, greater cushioning, improved abrasion resistance, or a balanced mix of all these aspects.
Anatomical support, shock absorption, stability and lightness
Every custom orthopedic sole for footwear designed by PBS Soles is based on a clearly defined technical balance. The company focuses on four key parameters:
- Anatomical support
The shape of the sole is studied to follow the natural profile of the foot and to integrate with custom insoles and footbeds. This helps promote a more correct foot placement, improving posture and load distribution. - Shock absorption
Materials such as microporous compounds and EVA help reduce impact at each step, limiting stress on joints, knees and back. This is especially important for people who walk for many hours a day or have joint-related problems. - Stability and lightness
The sole must be stable, but not heavy. The goal is to ensure a safe gait without overloading the foot. Thickness, profile and contact areas are engineered to balance these two aspects. - Adaptability to contoured insoles and footbeds
Orthopedic footwear often includes custom-made insoles. PBS Soles’ soles are designed to properly accommodate them, integrating additional thicknesses, corrections and lifts required by the orthopedic project.
Integration with custom insoles and contoured footbeds
An effective orthopedic sole never works in isolation. To be truly functional, it must integrate perfectly with custom insoles and contoured footbeds. For this reason, PBS Soles:
- works closely with footwear manufacturers and orthopedic technicians to understand the project’s specific needs;
- produces soles with volumes and thicknesses designed to house custom insoles;
- designs the sole profile in relation to heel height, foot roll and the required corrections.
This approach reduces the risk of incompatibility between components and improves the final result in terms of comfort and functionality.
Specific orthopedic projects and production flexibility
Every orthopedic case is unique. Therefore, custom orthopedic soles for footwear must be able to adapt to:
- footwear for diabetic or sensitive feet;
- post-operative or recovery shoes;
- orthopedic footwear for daily use;
- solutions for elderly people or those with reduced mobility.
PBS Soles offers a flexible production setup that allows the manufacturing of personalized soles even in relatively small batches starting from 400 pairs, making it easier to develop dedicated orthopedic lines or to produce for brands specialising in comfort and foot wellbeing.
PBS Soles as a technical partner for custom orthopedic soles
Choosing an experienced partner in the production of custom orthopedic soles for footwear means relying on technical expertise, material knowledge and the ability to translate orthopedic requirements into a sole that is truly functional.
PBS Soles supports footwear manufacturers and brands in:
- selecting the most suitable material (microporous, EVA, technical rubber, or combinations);
- defining thicknesses, hardness levels and sole geometries;
- prototyping and on-shoe testing;
- managing industrial production, while maintaining consistent quality over time.
Because in orthopedics every millimeter counts, and the sole must work in harmony with the foot.
Contact us to develop new custom orthopedic soles for footwear for your shoes, designed to improve posture, comfort and walking quality for your customers.