Often times, we have heard that skaters sent casts to boot companies and are told the boots will be made off the cast itself. Unfortunately, it is untrue. A boot can not be made from a plaster cast.
Full positive casts are helpful for a three dimensional presentation of the skaters feet, and help identify abnormalities such as bunions, hammer toes, navicular spurs, haglund's deformities (heel spurs), large or pointed anklebones, and flat or low arches. However, due to the construction of footwear, the boots need to be made with a Last. A Last is a wooden or plastic foot shape that is unique to a manufacturers particular sizing.
The Last controls the shape of the toe box, arch, heel and determines the height of the boot heel. The top part of the boots, called the upper, is pulled over the Last and attached to the insole. The insole itself is nailed to the Last.
Once the boot is lasted, the soles are attached by gluing and high pressure pressing. The soles are pressed on with 1,000 ... more.
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