Foot Orthosis Having Sulcus Support and Methods for Making Same

A foot orthotic designed to unweight the ball of the foot, or more precisely the foot region of one or more of the five metatarsal heads, to alleviate pain while walking or standing. Using a connector from the foot orthotic to a sulcus bar provides a reproduceable front to back position of the sulcus bar relative to the foot orthotic. In certain aspects of the invention the connector provides further unweighting of the metatarsal heads, and also ensures a specific custom position of the sulcus bar throughout the foot orthotic fabrication process. Various methods of manufacturing an orthotic are also disclosed.