Stay tuned! I have been re-formulating my practice from the ground up! For the past year I have been sending the casts to Germany for CAD/CAM milling of wood lasts from 3D scans of your individually molded feet. The system works extremely well, and I will be revamping this site to reflect the the latest methods in European techniques! (October 15, 2017)
I am Kevin Leahy, and this is the introduction to a new paradigm in bespoke footwear in America. Up until now, bespoke footwear required either a last (foot form) that was pulled off a shelf and modified for your foot, or plaster foot casts that are modified into lasts. A few high-end bootmakers in London and continental Europe will hand-carve wood lasts from scratch, but this is very expensive ($5,000 and up). But quite frankly, if you have orthopedic issues, the finished shoes, though beautiful, may not meet your needs. Plaster casts are fragile, and most bootmakers will not work with plaster.
The ideal would be to scan an exact image of the foot into a computer, model the toe shape, orthopedic features and fit in the computer, then have wood lasts milled by computer for your feet. This is what I now offer. Casts are taken of your feet, your casts are then 3D scanned into a computer, your desired toe shape and heel height are applied to your 3D foot images, and then beautiful wood lasts are CNC machined from your 3D files. Then orthotic arch supports are molded to your lasts and custom cut and sewn uppers (the top part of the shoe or boot) are made from European leathers.
So now you can have old-world craftsmanship combined with state of the art 3D imagery of your feet!
In addition, I am offering designs that have been difficult to find in footwear made from foot casts. Individual crafts people, called upper makers, design elegant patterns to ensconse your feet in luxurious European leathers. They will draw the design on your lasts, make patterns and then cut and sew the leather to fit your feet. After a fitting with your custom arch supports molded to your lasts, I then stretch the leather sewn by the upper makers around your orthotics and lasts. I finish your shoes or boots with the sole and heel of your choice. Sound complicated? Not really. I will evaluate your feet and guide you through process of choosing the style and other options.
The process of boot and shoe upper making explained: Boot and Shoe Upper Making
Need more info? Check out my reviews on my other website.