From Pain to Relief: Treating Rigid Feet with Custom Orthotics

If you’re struggling with foot pain—especially due to age, arthritis, or years of wear and tear—the right orthotic solution can make all the difference. In Episode 9 of "Workshop Live," Tony Chips dives into a hands-on review of a common but often-misunderstood issue: the rigid, aging foot (referred to as an "A1 foot type") and the meticulous modifications that go into solving persistent pain.

Below, we’ll break down how Tony’s approach directly addresses foot discomfort, plus the importance of custom tailoring orthotics for real-world relief.

Tony introduces a customer with an "A1 foot type": a bony, rigid foot that has become increasingly stiff over the years. This foot has seen plenty of action and, as he points out, has developed issues in both the toes and forefoot. The customer’s history includes previous orthotics, but with changed needs and added pain, it was time for a new solution—one involving more cushioning and strategic support.

The condition of rigid feet often leads to rigid feet pain, particularly in areas where the joints no longer flex naturally. This lack of mobility can make walking, standing, or even wearing standard footwear uncomfortable—especially as foot rigidity increases with age or past injuries.

Recognizing that stiff feet lack natural shock absorption, Tony selected a four-layer custom orthotic:

• EVA Top Cover: Known for comfort and a soft touch against the foot.
• Eco Cell Pulse: Excellent shock absorption, crucial for aging, less flexible feet.
• EVA FM: Provides strong underlying support so the foot doesn’t collapse further.
• Cork Base: Adds a firm but accommodating foundation.

This thoughtful layering isn't arbitrary—it’s tailored to absorb impact, redistribute pressure, and address pain points unique to a rigid, previously pronated foot.

During a two-week checkup, the customer shared their progress: good comfort on the left foot but ongoing cramping and metatarsal pain on the right.

Here’s how Tony dialed in on the solution:

• Forefoot Padding: Padded both left and right forefoot with professional-grade “pour-on” for consistent cushioning.
• Cuboid Bar: Added to the right side, this small addition targets pressure under the fifth metatarsal (outside of the foot) for better balance and reduced irritation.
• Extra Metatarsal Pad: By doubling up the metatarsal pad below the second, third, and fourth toes (key pain areas), Tony relieves pressure and encourages the foot to spread naturally with each step.

The materials used (55 durometer EVA and cushioned cork) strike the right balance—soft enough for comfort, but firm enough for real support.

Understanding the difference between rigid feet vs flexible feet is essential when it comes to treatment. Rigid feet, often the result of aging, arthritis, or structural foot abnormalities, tend to be stiff with limited joint movement. These feet struggle to absorb shock and adapt to uneven terrain, which leads to increased stress on other joints like the knees and hips.

In contrast, flexible feet are more adaptable and can distribute pressure more evenly. While flexible feet can also experience problems (like overpronation), they usually benefit more quickly from simple orthotic support.

For rigid foot types , the approach must be much more strategic. Modifications need to carefully manage foot rigidity, redistribute pressure, and offer both shock absorption and control.

If you or someone you know is experiencing rigid feet pain, our certified pedorthic experts are here to help! We offer free foot assessments, make custom orthotics in-house, and provide free orthotic adjustments.