In 2025, iOrthotics introduced an update to how forefoot extensions are finished on EnviroPoly devices, responding to the increasing variety of modern footwear, particularly anatomical toe boxes and sandal-style designs.
The key change is a slight oversizing of the forefoot extension in the default full-length option.
This provides greater adaptability across different shoe shapes while still allowing the lab to refine designs in the custom shell. Standard template sizing reference is maintained with the finishing team to support accurate placement of modifications such as plantar metatarsal pads (PMPs), met domes/bars and reverse Morton’s extensions.
For those wanting a closer-to-shoe-ready finish, the full length – iO template option remains available. This follows traditional iOrthotics size guides for templating and trimming, with final width still adjusted to the shell. In future, electing a template size and selecting ‘iO template’ will get you closer to a shoe-ready device, although fitting and adjustment in clinic is always advised.
A simple in-clinic adjustment can further refine the fit: remove the shoe liner and align it with the orthotic shell (rather than the cover), trace the forefoot extension, and trim using scissors. If available, a quick finish on a grinder can help achieve a cleaner, more aesthetic edge.
It’s important to note that these changes apply to EnviroPoly devices only. EVA and EnviroFoam options continue to be manufactured to their prescribed dimensions, with Envirofoam providing the closest to shoe-ready device.
Overall, this update reflects a shift toward more adaptable orthotic finishing and allows us to keep up with the broader industry- supporting better integration with the footwear patients are actually wearing, while still allowing for precise, clinician-led adjustments where needed.
