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Custom Orthotics in Northern Vermont

Tired of generic orthotics that don’t fit properly or provide lasting relief? Experience same-day custom orthotic fabrication in your home with immediate adjustments until they’re perfect.

No more waiting weeks for ill-fitting inserts. Call (802) 330-1491 for on-site orthotic fabrication.

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Custom Orthotics Near Me In North Vermont

What you'll find on this page

Looking For Custom Orthotics?

Kōkua Physical Therapy brings professional orthotic fabrication directly to your home using portable equipment and advanced materials. Our founder, Dr. Teddy Zabel, has specialized training in custom orthotic fabrication and foot and ankle dysfunction, creating hand-crafted foot orthoses for everything from ski boots to hiking shoes.

Our custom-fabricated orthotic services in Northern Vermont include complete foot/ankle evaluation, on-site fabrication using thermoplastic molds, and immediate adjustments for perfect fit in Burlington, Stowe, Cambridge, Jeffersonville, Essex, South Burlington, Hyde Park, Morristown, and throughout Chittenden and Lamoille Counties. To see all areas we service, click here.

Ready for orthotics that actually work? Call (802) 330-1491 today.

Reasons to choose kokua

What Custom Orthotic Services Do You Offer?

We fabricate custom orthotics on-site using professional-grade materials including thermoplastic molds, thermal cork, nickel plast, plastazoate, and poron to create inserts that meet your unique anatomical variants. Unlike generic pre-fabricated inserts, our hand-crafted foot orthoses are molded specifically to your foot and built to accommodate your individual anatomical needs.

On-Site Custom Orthotic Fabrication

  • Complete foot/ankle/lower extremity evaluation
  • Thermoplastic molding to your exact foot structure
  • Professional materials (thermal cork, nickel plast, plastazoate, poron)
  • Immediate adjustments based on your feedback
  • Perfect fit guarantee before you leave
  • Works for shoes, hiking boots, ski boots, work boots

Conditions We Treat With Custom Orthotics

  • Flat feet (excessive pronation)
  • Plantar fasciitis and heel pain
  • Metatarsalgia and forefoot pain
  • Bunions and toe deformities
  • Heel spurs and
  • Morton’s neuroma
  • Leg length discrepancies
  • Balance issues in older adults
  • Ski boot fitting and comfort
  • Arthritis and joint degeneration
  • Ligament tears and post-injury support

Experience custom orthotics made perfectly for you. Call (802) 330-1491 to schedule.

Why Should I Choose Kōkua for Custom Orthotics?

We’re the only provider in Northern Vermont offering professional custom orthotic fabrication in your home with same-day fitting and unlimited adjustments.

6 Reasons to Choose Kōkua Orthotics:

The biggest frustration I hear is having to wait weeks for orthotics while you’re still in pain. You get an impression made, they send it to a lab, and you wait 2-4 weeks hoping they’ll fit. I bring all the fabrication equipment to your home so we make your orthotics on the spot. You walk away in two hours with orthotics ready to use, not starting a month-long waiting game.

Most orthotics come from labs, and if they don’t feel right, you’re stuck. I’ve had so many people tell me “my orthotics hurt more than help.” What I do is have you try them on during the appointment and tell me how they feel. If there’s a pressure point, I adjust it immediately with my equipment. We keep tweaking until they feel perfect because I can actually fix it in real-time.

There’s a huge difference between professional materials and what most providers use. I use the exact same materials – thermal cork, plastazoate, poron – that orthotic specialists use. These aren’t cheap foam that breaks down after months. Most providers don’t have access to these materials or the training to use them properly, so you get something that looks like an orthotic but doesn’t perform like one.

Most foot pain isn’t coming from where you feel it. I spend two hours really understanding what’s going on – not just where it hurts, but why. I’m looking at how you walk, your anatomy, things like forefoot varus or excessive pronation. Most providers work under time constraints or don’t have specialized training to identify these complex issues, so they treat symptoms instead of fixing the actual problem.

I guarantee your orthotics will be comfortable before you leave because I can actually make that happen. With traditional providers, you pay and hope they fit when they come back from the lab. Since I’m fabricating them with you there, I keep adjusting until they feel exactly right. There’s no reason to leave with uncomfortable orthotics when I have the equipment to fix whatever needs fixing.

What sets me apart is my specialized training specifically in foot and ankle dysfunction. I’m board certified in orthopedics with advanced coursework in custom orthotic fabrication. Most therapists have general training, but I’ve spent years learning about anatomical variants like forefoot varus and pronation patterns. When orthotics haven’t worked before, it’s often because the provider didn’t have the expertise to identify the real problem.

How Do Custom Orthotics Compare to the Traditional Healthcare System?

Traditional System Kokua Physical Therapy
Timeline 4-6 weeks minimum 2 hours, same day
Appointments 4-6 visits over 2+ months 1 visit (follow-up if needed)
Evaluation 15-30 minutes, rushed 2 hours, comprehensive
Manufacturing Lab technician who's never met you The same person who evaluated you
Adjustments Hope they fit, schedule more appointments if not Real-time adjustments until perfect
Insurance Prior authorization delays, documentation requirements Cash-pay, no delays or restrictions
Provider Expertise Separate podiatrist and PT if needed Combined PT and orthotic fabrication training
Communication Provider → Lab → Patient (gaps common) Direct relationship throughout
Materials Whatever the lab chooses Professional-grade, selected for your needs
Cost Basic exercise a$400-600 + office visits + adjustments $350 total, everything included

When Are Custom Orthotics The Right Choice For Me?

Custom orthotics are ideal if you have foot pain, knee pain caused by foot problems, or need specialized inserts for activities like skiing or hiking that generic options can’t address.

You’re a perfect candidate if you have:

  • Flat feet or excessive pronation causing pain
  • Plantar fasciitis, heel spurs, or chronic foot pain
  • Knee pain that worsens with walking or standing
  • Balance issues or instability while walking
  • Need orthotics for ski boots, hiking boots, or work boots
  • Generic store-bought inserts haven’t helped
  • Arthritis affecting foot or ankle joints
  • Ligament injuries requiring support

Real Results: 

A client of ours came to us with chronic foot pain that made skiing unbearable. During our evaluation, we identified forefoot varus causing excessive pronation and knee instability. We fabricated custom ski boot orthotics with a medial wedge to correct the pronation. After immediate adjustments for perfect comfort, he returned to pain-free skiing the same weekend.

Don’t let foot pain limit your Vermont activities. Call (802) 330-1491 for your evaluation.

How Much Does It Cost?

Our custom orthotic fabrication service is $350 for the complete process, including evaluation, fabrication, fitting, and all necessary adjustments.

What’s Included:

  • Complete foot/ankle/lower extremity evaluation (identifies pain source)
  • Professional custom orthotic fabrication using specialized materials
  • Perfect fitting with immediate adjustments
  • Follow-up visit if needed for additional modifications
  • 2-hour appointment with same-day completion

Value Comparison:

While generic orthotics cost $50-200 and often don’t work, our custom orthotics address your specific anatomical variants for long-term relief. Most patients save money by avoiding repeated purchases of ineffective store-bought options.

Invest in orthotics that actually solve your problem. Call (802) 330-1491 for professional fabrication.

How Do I Get Custom Orthotics Made?

Our custom orthotic fabrication process ensures perfect fit and function through systematic evaluation, molding, and adjustment:

Step 1: Comprehensive Foot/Ankle Evaluation

  • Complete assessment of foot structure and anatomical variants

  • Identify true cause of pain (often excessive pronation or forefoot varus)

  • Measure exact foot dimensions and pressure points

  • Determine specific orthotic needs for your activities

Step 2: Professional Fabrication

  • Heat thermoplastic molds to 275 degrees for precise foot molding
  • Build orthotic using professional materials (thermal cork, plastazoate, poron)
  • Create specific corrections (medial wedges, arch support, pressure relief)
  • Craft orthotics specifically for your shoes/boots

Step 3: Fitting and Immediate Adjustments

  • Try on custom orthotics and test comfort/function

  • Make real-time adjustments based on your feedback

  • Perfect fit guarantee before you leave

  • Instructions for break-in period and care

     

Step 4: Follow-Up Support

  • Follow-up visit included if modifications needed

  • Ongoing support for any comfort issues

  • Advice on activity progression and orthotic care

Do You Have Guarantees/Warranties?

We believe in our custom orthotic fabrication process and want you to be completely satisfied with your investment.

Our Promises:

  • Perfect fit guarantee – we adjust until they’re comfortable before you leave
  • Professional materials and techniques used by orthotic specialists
  • Same-day completion – no waiting weeks for poorly fitting lab orthotics
  • Follow-up included if additional modifications are needed after use

The Hawaiian concept of mālama means to care for what’s important. Your comfort and mobility are important to us.

Frequently Asked Questions

Custom orthotics typically cost $400-600 through traditional healthcare providers, plus additional fees for office visits, casting, and adjustments. Our complete service is $350 total, including evaluation, fabrication, fitting, all adjustments, and follow-up care.

Custom orthotics have an 89% success rate for conditions like plantar fasciitis and can eliminate the need for repeated purchases of ineffective over-the-counter options. Most patients save money long-term by avoiding multiple failed solutions and getting lasting relief.

Traditional providers charge for multiple appointments, laboratory fees, casting materials, and technician time spread across 4-6 weeks. Our pricing includes professional materials, specialized fabrication equipment, expert evaluation, and immediate adjustments – all delivered in one 2-hour appointment.

Custom orthotics typically last 2-5 years with proper care. The professional materials we use (thermal cork, plastazoate, poron) are designed for durability and can be adjusted or refurbished as needed.

We’re a cash-based service to eliminate delays and restrictions. While insurance coverage for orthotics varies dramatically (50-90% when covered), many patients find our direct-pay model more cost-effective than navigating insurance requirements, prior authorizations, and out-of-pocket costs.

Without insurance, custom orthotics cost $400-800 through traditional providers, plus office visits ($100-200), casting fees ($50-150), and adjustments ($50-100). Our $350 all-inclusive price is often less than traditional out-of-pocket costs.

We bring professional fabrication equipment to your home for a 2-hour appointment. After a comprehensive evaluation, we heat thermoplastic molds to 275 degrees, create your orthotics using professional materials, and make immediate adjustments based on your feedback until they’re perfect.

Properly fitted custom orthotics should be comfortable immediately. Since we make real-time adjustments during your appointment, you leave with orthotics that feel right. Any minor adaptation period is typically just a few days, not weeks.

Our complete custom orthotic process takes 2 hours from evaluation through final fitting. Traditional providers require 4-6 weeks with multiple appointments. You walk away the same day with orthotics ready to use.

We design your orthotics for your specific footwear needs, whether that’s dress shoes, hiking boots, or ski boots. During evaluation, we discuss your shoe requirements and craft orthotics that work with your lifestyle.

Mild discomfort during therapeutic exercise is normal and expected, but sharp or severe pain indicates the need for treatment modification to ensure safe progress.

Physical therapy is highly effective for pinched nerve treatment when properly diagnosed, using the McKenzie Method, manual therapy, and exercises to reduce nerve compression and restore mobility.

Physical therapy achieves excellent outcomes for bulging disc management using specialized techniques like the McKenzie Method and specific exercises to reduce disc pressure and strengthen supporting structures.

Physical therapists offer a more comprehensive approach to bulging disc treatment with exercise prescription, patient education, and long-term movement pattern correction compared to chiropractic care alone.

mobile physical therapy in northern vermont

What do our PATIENTS say about us?

counties, cities & towns we serve in vermont

Become pain-free in the comfort of your home

Chittenden County

Lamoille County

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