Bring Your Orthotics Back to Life with a Simple DIY Revival
Orthotic insoles are a daily lifeline for millions, offering support, alignment, and comfort. But over time, the top covers—the soft upper layer of your orthotics—begin to show wear. From peeling edges to flattened cushioning, these signs of use can drastically affect how your orthotics feel and perform. Thankfully, you don’t need to invest in a new pair. With the right approach, you can revive your orthotic top covers and restore them to their former glory—or even improve them.

In this comprehensive refurbishing orthotics top covers guide, we’ll walk you through the exact steps and materials needed to transform your orthotics from worn-out to wonderful.

Why Refurbish Instead of Replace?
Refurbishing orthotic top covers comes with several key benefits:

Cost savings: Refurbishment is significantly cheaper than purchasing new orthotics.

Customization: You can upgrade the comfort by using better materials than the original.

Sustainability: Reducing waste by reusing the orthotic shell helps the environment.

Faster turnaround: Refurbishing takes hours, not weeks, unlike ordering a new custom pair.

Step 1: Assess the Damage
Before you begin, take a close look at your orthotics. Signs that the top covers need attention include:

Tears, peeling, or separation at the edges

Faded, compressed, or hardened foam

Persistent odors despite cleaning

Increased foot discomfort or pressure points

If the rigid base of the orthotic is still in good condition, refurbishing is the ideal solution.

Step 2: Remove the Worn Top Cover
Gently peel off the old top layer using a plastic scraper or dull blade. If any adhesive remains, apply a remover like Goo Gone or isopropyl alcohol to dissolve it. Thoroughly clean the surface with a mild detergent and let it dry completely.

Step 3: Select a Better Top Cover Material
Choosing the right material can enhance comfort, durability, and performance. Top choices include:

Poron® or EVA foam – Lightweight, flexible, and absorbs shock

Neoprene or Spenco® fabric – Moisture-wicking and great for athletes

Genuine leather – Durable, breathable, and ideal for formal use

Memory foam – Molds to your foot for superior personalized comfort

Cut the new top cover material to match your orthotic’s shape. Use the old one as a template if available.

Step 4: Use Professional-Grade Adhesive
Apply a thin layer of high-bond contact cement or medical-grade adhesive to both the orthotic base and the new cover material. Allow both surfaces to become tacky, then press firmly together, starting from one end to the other to avoid air bubbles.

Step 5: Secure the Edges and Reinforce High-Wear Areas
Trim any excess material with a precision blade for a snug fit. For areas that experience more stress (like the heel or ball of the foot), consider:

Adding gel inserts or heel cups underneath the new top layer

Doubling up on foam for better shock absorption

Applying a thin line of seam sealant along the edge to prevent future peeling

Step 6: Let It Cure and Test the Fit
Allow the adhesive to cure fully—usually 12 to 24 hours. Once ready, place the orthotics back in your shoes and take them for a walk. Notice how the fresh padding improves your comfort and support, especially if you’ve been dealing with fatigue or soreness from worn-out covers.

Bonus Tip: Refresh Your Orthotics Regularly
To keep your orthotics in top condition:

Clean them weekly with a damp cloth and mild soap

Air them out after each wear to prevent moisture buildup

Consider rotating between two pairs if you wear orthotics daily

Your Orthotics, Better Than New
Refurbishing your orthotic top covers isn’t just about saving money—it’s about extending the life of a tool that supports your body every single day. With the right tools, materials, and a bit of time, you can bring your insoles back to life—and step forward in lasting comfort.