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Comparing Clinical Outcomes Using Two Insole Manufacture Techniques

Comparing the Effectiveness of Computer-aided-design Computer-aided-manufacture (CAD/CAM) Insoles Manufactured From Foam-box Cast vs Direct Scan on Patient Reported Outcome Measures: A Double-blinded, Randomised Controlled Trial

Status
Completed
Phases
NA
Study type
Interventional
Source
ClinicalTrials.gov
Registry ID
NCT05444192
Enrollment
114
Registered
2022-07-05
Start date
2022-09-29
Completion date
2023-11-24
Last updated
2025-05-23

For informational purposes only — not medical advice. Sourced from public registries and may not reflect the latest updates. Terms

Conditions

Feet, Flat, Foot Ankle Injuries, Foot Deformity, Foot Injury, Foot Sprain

Brief summary

The main purpose of this study is to find out if scanning the foot using a 3D scanner influences the effectiveness of custom made insoles, compared to the more traditional approach of taking a foam-box impression cast of the foot. Both of these methods are currently used as standard care in the NHS Greater Glasgow and Clyde (GGC) Orthotic Department. In this study, insoles will be manufactured either from a direct 3D scan of the foot, or from a foam-box impression cast, and a series of questionnaires will be used to measure any changes in foot pain and foot function. The results from this study will be used to develop an information resource for both patients and Orthotists which will fill gaps in our current knowledge and hopefully guide us further in providing the best possible care for future patients who require insoles.

Detailed description

A single centre, double blinded, randomised controlled trial. Interventional, equivalence Trial design. Participants will be asked to attend 2 face-to-face appointments for assessing and fitting of insoles, which is standard practice in the NHS GGC Orthotic Department. Each face-to-face appointment will take approximately 40 minutes. Following the fitting of the insoles, participants will be asked to participate in 3 telephone calls over 12-weeks, during which they will be asked to answer questions from two questionnaires (the Foot Health Status Questionnaire, and the Orthotic and Prosthetic User Survey). Each telephone appointment will take approximately 15 minutes. Once participants receive their insoles, they will also be asked to keep a diary detailing the number of hours that they wore the insoles each day over 12-weeks. This information will be collected by the Orthotist involved with the trial during the telephone review appointments.

Interventions

DEVICECAD/CAM insoles

computer-aided-design computer-aided-manufacture (CAD/CAM) insoles

Sponsors

University of Central Lancashire
CollaboratorOTHER
NHS Greater Glasgow and Clyde
Lead SponsorOTHER

Study design

Allocation
RANDOMIZED
Intervention model
PARALLEL
Primary purpose
TREATMENT
Masking
DOUBLE (Subject, Investigator)

Eligibility

Sex/Gender
ALL
Age
18 Years to No maximum
Healthy volunteers
No

Inclusion criteria

* Are aged 18 years or above * Are referred to the NHS GGC Orthotic service requiring a new assessment for insoles * are deemed suitable for CAD/CAM insoles as assessed by the PI or Co-I on clinical assessment * Are able to commit to five appointments over a 16-week period (two Face-to-Face appointments, three Telephone Appointments) * Have suitable own footwear that can accommodate a CAD/CAM insole as assessed by the PI or Co-I, and as per standard practice can wear these for 12-weeks * Is willing to allow their General Practitioner and consultant, if appropriate, to be notified of participation in the trial. * An adequate understanding of written and verbal information in English in order to provide informed consent and answer the study questionnaires

Exclusion criteria

* Scheduled elective surgery or other procedures which is likely to affect mobility during the trial. * Scheduled steroid injection of the foot or ankle up to 3 months prior to joining the trial, or during participation in the trial * Age \<18 years * Adult with Incapacity, under The Adults with Incapacity (Scotland) Act 2000 * Participant unable or unwilling to consent * Medial longitudinal Arch height of the foot exceeds depth of EVA blank (35mm) * Clinical assessment concludes that the participant requires an insole material other than EVA * Clinical assessment concludes that the participant does not require or will be unlikely to benefit from CAD/CAM insoles. * The participant is unable to commit to the trial conditions. * Peripheral Neuropathy present * Active foot ulceration present * Participant with life expectancy of less than 6 months. * Any other significant disease or disorder which, in the opinion of the PI or Co-I, may either put the participants at risk because of participation in the trial, or may influence the result of the trial, or the participant's ability to participate in the trial. * Participants who have participated in another research trial involving an investigational foot orthosis in the past 12 weeks.

Design outcomes

Primary

MeasureTime frameDescription
Foot Health Status Questionnaire (FHSQ) - Pain Sub-domainMeasured 4 times throughout the 12-week period that the participant is wearing the insoles: Baseline immediately after receiving intervention (insoles). 4 weeks after intervention. 8 weeks after intervention. And 12 weeks after interventionTo compare the changes in pain in two groups of participants fitted with custom CAD/CAM insoles manufactured using different foot shape capture methods. Units on a scale. Minimum score is 0, maximum score is 100. Higher scores represent better outcomes.

Secondary

MeasureTime frameDescription
Foot Health Status Questionnaire (FHSQ) - Function Sub-domainMeasured 4 times throughout the 12-week period that the participant is wearing the insoles: Baseline immediately after receiving intervention (insoles). 4 weeks after intervention. 8 weeks after intervention. And 12 weeks after interventionTo compare the changes in foot function in two groups of participants fitted with custom CAD/CAM insoles manufactured using different foot shape capture methods. Units on a scale. Minimum score is 0, maximum score is 100. Higher scores represent better outcomes.
Foot Health Status Questionnaire - Foot Health Sub-domainMeasured 4 times throughout the 12-week period that the participant is wearing the insoles: Baseline immediately after receiving intervention (insoles). 4 weeks after intervention. 8 weeks after intervention. And 12 weeks after interventionTo compare the changes in foot health in two groups of participants fitted with custom CAD/CAM insoles manufactured using different foot shape capture methods. Units on a scale. Minimum score is 0, maximum score is 100. Higher scores represent better outcomes.
Orthotic and Prosthetic User Survey9-12 (Satisfaction With Device Survey)Measured 12 weeks after being fitted with insolesTo compare the patient satisfaction in two groups of participants fitted with custom CAD/CAM insoles manufactured using different foot shape capture methods. Units on a scale. Minimum score is 0, maximum score is 100. Higher scores represent better outcomes.
Differential Cost AnalysisCosts were calculated per participant from baseline until their completion of the trial at week 12.A differential cost analysis was undertaken. This involved calculating the total cost for each participant using a calculation of transit costs, staff time, and physical resources for each participant throughout their time in the trial.

Other

MeasureTime frameDescription
Tertiary Outcome Measure - Hours of Insole Wear Time Per DayMeasured from baseline until completion of the trial at week 12Patients will keep a diary of daily wear time in hours, in accordance with prior publications on measuring Orthotic Adherence. The minimum threshold for adherence is \>21 hours per week
Tertiary Outcome Measure - Dropout RateMeasured from baseline to completion of the trial at 12 weeks, for each participantDropout rate = n dropout at end of trial

Countries

United Kingdom

Participant flow

Pre-assignment details

Assessed for eligibility (n=118) Excluded (n=4) * Already has suitable insoles (n=2) * Not suitable for treatment with insoles (n=1) * Declined to participate (n=1)

Participants by arm

ArmCount
Insoles Manufactured From Foam-box Cast
Both arms are currently standard treatment within the NHS GGC Orthotic Department. There are no experimental interventions in the study. CAD/CAM insoles: computer-aided-design computer-aided-manufacture (CAD/CAM) insoles
57
Insoles Manufactured From Direct 3D Scan
Both arms are currently standard treatment within the NHS GGC Orthotic Department. There are no experimental interventions in the study. CAD/CAM insoles: computer-aided-design computer-aided-manufacture (CAD/CAM) insoles
57
Total114

Withdrawals & dropouts

PeriodReasonFG000FG001
Overall StudyLost to Follow-up10

Baseline characteristics

CharacteristicInsoles Manufactured From Foam-box CastInsoles Manufactured From Direct 3D ScanTotal
Age, Continuous50.0 years50.0 years50.0 years
Area of primary musculoskeletal pathology
Ankle
21 Participants24 Participants45 Participants
Area of primary musculoskeletal pathology
First ray
3 Participants10 Participants13 Participants
Area of primary musculoskeletal pathology
Forefoot
17 Participants10 Participants27 Participants
Area of primary musculoskeletal pathology
Lower leg
0 Participants1 Participants1 Participants
Area of primary musculoskeletal pathology
Midfoot
4 Participants1 Participants5 Participants
Area of primary musculoskeletal pathology
Plantar heel / plantar fascia
12 Participants11 Participants23 Participants
Race/Ethnicity, Customized
Ethnicity
African
1 Participants0 Participants1 Participants
Race/Ethnicity, Customized
Ethnicity
Other (mixed)
0 Participants1 Participants1 Participants
Race/Ethnicity, Customized
Ethnicity
White
56 Participants56 Participants112 Participants
Sex: Female, Male
Female
41 Participants41 Participants82 Participants
Sex: Female, Male
Male
16 Participants16 Participants32 Participants

Adverse events

Event typeEG000
affected / at risk
EG001
affected / at risk
deaths
Total, all-cause mortality
0 / 570 / 57
other
Total, other adverse events
7 / 572 / 57
serious
Total, serious adverse events
0 / 570 / 57

Outcome results

Primary

Foot Health Status Questionnaire (FHSQ) - Pain Sub-domain

To compare the changes in pain in two groups of participants fitted with custom CAD/CAM insoles manufactured using different foot shape capture methods. Units on a scale. Minimum score is 0, maximum score is 100. Higher scores represent better outcomes.

Time frame: Measured 4 times throughout the 12-week period that the participant is wearing the insoles: Baseline immediately after receiving intervention (insoles). 4 weeks after intervention. 8 weeks after intervention. And 12 weeks after intervention

ArmMeasureGroupValue (MEDIAN)
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire (FHSQ) - Pain Sub-domain12 weeks following intervention78.13 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire (FHSQ) - Pain Sub-domain8 weeks following intervention72.50 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire (FHSQ) - Pain Sub-domain4 weeks following intervention72.50 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire (FHSQ) - Pain Sub-domainBaseline48.13 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire (FHSQ) - Pain Sub-domainBaseline53.75 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire (FHSQ) - Pain Sub-domain12 weeks following intervention78.75 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire (FHSQ) - Pain Sub-domain4 weeks following intervention78.13 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire (FHSQ) - Pain Sub-domain8 weeks following intervention78.13 units on a scale
Secondary

Differential Cost Analysis

A differential cost analysis was undertaken. This involved calculating the total cost for each participant using a calculation of transit costs, staff time, and physical resources for each participant throughout their time in the trial.

Time frame: Costs were calculated per participant from baseline until their completion of the trial at week 12.

ArmMeasureValue (MEAN)
Insoles Manufactured From Foam-box CastDifferential Cost Analysis55.46 cost in pounds and pence per participant
Insoles Manufactured From Direct 3D ScanDifferential Cost Analysis44.94 cost in pounds and pence per participant
Secondary

Foot Health Status Questionnaire (FHSQ) - Function Sub-domain

To compare the changes in foot function in two groups of participants fitted with custom CAD/CAM insoles manufactured using different foot shape capture methods. Units on a scale. Minimum score is 0, maximum score is 100. Higher scores represent better outcomes.

Time frame: Measured 4 times throughout the 12-week period that the participant is wearing the insoles: Baseline immediately after receiving intervention (insoles). 4 weeks after intervention. 8 weeks after intervention. And 12 weeks after intervention

ArmMeasureGroupValue (MEDIAN)
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire (FHSQ) - Function Sub-domain12 weeks following intervention87.50 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire (FHSQ) - Function Sub-domain8 weeks following intervention75.00 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire (FHSQ) - Function Sub-domain4 weeks following intervention87.50 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire (FHSQ) - Function Sub-domainBaseline68.75 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire (FHSQ) - Function Sub-domainBaseline62.50 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire (FHSQ) - Function Sub-domain12 weeks following intervention93.75 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire (FHSQ) - Function Sub-domain4 weeks following intervention87.50 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire (FHSQ) - Function Sub-domain8 weeks following intervention93.75 units on a scale
Secondary

Foot Health Status Questionnaire - Foot Health Sub-domain

To compare the changes in foot health in two groups of participants fitted with custom CAD/CAM insoles manufactured using different foot shape capture methods. Units on a scale. Minimum score is 0, maximum score is 100. Higher scores represent better outcomes.

Time frame: Measured 4 times throughout the 12-week period that the participant is wearing the insoles: Baseline immediately after receiving intervention (insoles). 4 weeks after intervention. 8 weeks after intervention. And 12 weeks after intervention

ArmMeasureGroupValue (MEDIAN)
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire - Foot Health Sub-domain12 weeks following intervention60.00 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire - Foot Health Sub-domain8 weeks following intervention46.25 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire - Foot Health Sub-domain4 weeks following intervention42.50 units on a scale
Insoles Manufactured From Foam-box CastFoot Health Status Questionnaire - Foot Health Sub-domainBaseline25.00 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire - Foot Health Sub-domainBaseline42.50 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire - Foot Health Sub-domain12 weeks following intervention72.50 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire - Foot Health Sub-domain4 weeks following intervention60.00 units on a scale
Insoles Manufactured From Direct 3D ScanFoot Health Status Questionnaire - Foot Health Sub-domain8 weeks following intervention72.50 units on a scale
Secondary

Orthotic and Prosthetic User Survey9-12 (Satisfaction With Device Survey)

To compare the patient satisfaction in two groups of participants fitted with custom CAD/CAM insoles manufactured using different foot shape capture methods. Units on a scale. Minimum score is 0, maximum score is 100. Higher scores represent better outcomes.

Time frame: Measured 12 weeks after being fitted with insoles

ArmMeasureValue (MEAN)
Insoles Manufactured From Foam-box CastOrthotic and Prosthetic User Survey9-12 (Satisfaction With Device Survey)69.48 units on a scale
Insoles Manufactured From Direct 3D ScanOrthotic and Prosthetic User Survey9-12 (Satisfaction With Device Survey)76.35 units on a scale
Other Pre-specified

Tertiary Outcome Measure - Dropout Rate

Dropout rate = n dropout at end of trial

Time frame: Measured from baseline to completion of the trial at 12 weeks, for each participant

ArmMeasureValue (COUNT_OF_PARTICIPANTS)
Insoles Manufactured From Foam-box CastTertiary Outcome Measure - Dropout Rate2 Participants
Insoles Manufactured From Direct 3D ScanTertiary Outcome Measure - Dropout Rate0 Participants
Other Pre-specified

Tertiary Outcome Measure - Hours of Insole Wear Time Per Day

Patients will keep a diary of daily wear time in hours, in accordance with prior publications on measuring Orthotic Adherence. The minimum threshold for adherence is \>21 hours per week

Time frame: Measured from baseline until completion of the trial at week 12

ArmMeasureValue (MEAN)
Insoles Manufactured From Foam-box CastTertiary Outcome Measure - Hours of Insole Wear Time Per Day5.08 Hours
Insoles Manufactured From Direct 3D ScanTertiary Outcome Measure - Hours of Insole Wear Time Per Day6.09 Hours

Source: ClinicalTrials.gov · Data processed: Feb 6, 2026