Aortha PPC Foot Orthotic Blanks

Polypropylene Orthotic Shell Blanks

Ready-to-use orthotic blanks manufactured from high-performance Aortha PPC, designed to support efficient fabrication of durable, custom foot orthoses.

Best for: Clinics and workshops producing custom foot orthoses requiring controlled flexibility, impact resistance, and repeatable forming results.
Not ideal for: Applications requiring ultra-soft or cushioning-only materials without structural control.

• Consistent PPC formulation for predictable forming behaviour
• Pre-cut blank sizing to support deep heel cups
• Supplied in convenient multi-pair packs

What is it?

Aortha PPC Foot Orthotic Blanks are pre-shaped orthotic shells produced from copolymer polypropylene (PPC), a thermoplastic widely used in orthotic fabrication. PPC is known for its balanced combination of rigidity, impact resistance, and controlled flexibility, making it suitable for foot orthoses that must tolerate repeated loading without permanent deformation.

These blanks are supplied ready to thermoform, removing the need to cut from large sheets and helping standardise workshop processes. The material is formulated to yield under pressure and torque during gait, then return consistently to its original form, reducing the risk of distortion over time.

Who is it for?

This product is intended for professional and specialist users involved in the design, manufacture, or modification of custom foot orthoses. It is particularly suited to environments where efficiency, consistency, and material reliability are important.

What is it used for?

Aortha PPC Foot Orthotic Blanks are used as the structural shell component of custom foot orthoses. Once thermoformed, they provide a stable base that can be further finished, posted, or topped according to individual prescription requirements.

Typical applications

• Custom foot orthoses for everyday footwear
• Orthotic shells requiring directional rigidity
• Devices incorporating deep heel cups
• Clinical, sports, or occupational orthotic fabrication
• Educational and training settings for orthotic manufacture

Characteristics

• Lightweight with good structural rigidity
• High resistance to impact, cracking, and fatigue
• Thermoformable within standard PPC temperature ranges
• Returns to shape after loading without permanent deformation
• Available in multiple colours for identification or workflow preference

Typical users

• Orthotists and prosthetists
• Orthotic technicians and fabrication laboratories
• NHS and hospital in-house workshops
• Private podiatry and sports clinics
• Universities and training institutions
• Bespoke footwear makers and specialist technicians

How to work with it

The blanks are designed for standard thermoforming workflows. Once heated to the appropriate temperature range, the material becomes pliable and can be vacuum or pressure formed over a positive model or foot impression. After cooling, the PPC regains its structural properties and can be trimmed and finished as required.

Expected use timeline

First use: Once thermoformed and finished, the orthotic shell is ready for integration into a complete device. Initial fitting may highlight areas requiring minor adjustment or finishing.

Ongoing use: Over weeks of regular wear, the PPC shell is designed to tolerate repeated loading while maintaining its overall shape. As with all orthotic devices, periodic review is recommended to assess wear and suitability for continued use.

Common problems and how the product helps

Key benefits

• Efficient, ready-to-use format for busy workshops
• Balanced rigidity and flexibility for functional orthoses
• Robust performance under impact and cyclic loading
• Consistent thermoforming behaviour across batches
• Space-saving alternative to storing large PPC sheets
• Cost-effective option for small or high-turnover production

Common mistakes to avoid

• Overheating beyond recommended forming temperatures, which may affect material properties
• Assuming one shell design suits all clinical requirements without appropriate modification
• Skipping trial fitting and finishing steps after forming
• Using PPC where a significantly softer or more flexible material is required

Usage advice: How to use

Below is our recommended method of use with a standard Algeos vacuum press.

1. 1. Set oven temperature to 185°C.
   2. Remove protective film from both sides of the pre-cut  Polypropylene blank.
   3. Place on a flat surface in the oven. If possible allow 2cm of the polypropylene to hang over the edge of the heating shelf.
   4. Heat at 185°C for 6 minutes or until the overhanging polypropylene bends under it’s own weight to 45°.
   5. Transfer to the rectified plaster of paris cast on the platen of the Algeos vacuum press.
   6. Evacuate the air from the vacuum press as quickly as possible to avoid  trapped air on the surface of the moulding
   7. Allow the vacuum formed Polypropylene to cool naturally
   8. Trim and finish device as desired.

Technical specifications

Frequently asked questions

Can these blanks be used for sports orthoses?
They are commonly used in sports and activity-related orthoses where impact resistance and resilience are important.

Are the blanks suitable for deep heel cups?
Yes, the blank sizing and material characteristics support the formation of deeper heel cups when required.

How durable is PPC compared to other thermoplastics?
PPC is known for its resistance to cracking, impact, and general fatigue under repeated loading.

Do the blanks require special equipment?
Standard orthotic thermoforming equipment is suitable. No specialist machinery is required beyond typical workshop tools.

Will the material permanently deform over time?
The material is designed to yield under load and then return to its original shape, though periodic review of finished devices is recommended.

Are these suitable for teaching environments?
Yes, they are often used in training and educational settings due to their predictable forming behaviour.

Complementary and pairing suggestions

• Orthotic top cover materials for cushioning and comfort
• Posting materials for rearfoot or forefoot control
• Adhesives and finishing tools for orthotic fabrication
• Grinding and trimming consumables