When Exactly to Replace Your Orthotics—OTC or Custom
Walking on worn-out orthotics is like driving a car with flat tires—every step risks a breakdown, but when do you pull over to fix the problem?
Published April 28, 2025.
Orthotics, whether over-the-counter (OTC) or custom-made, are designed to support your feet, but they don’t last forever. Many people ignore subtle signs of wear or assume their discomfort is "normal," leading to worsening pain, misalignment, and even cascading issues like knee or back problems.
Knowing how long orthotics last—and when to replace custom orthotics specifically—can make the difference between staying pain-free and developing serious issues.
In this guide, you'll learn the critical signs your orthotics are failing, learn how OTC and custom varieties differ in lifespan, and get actionable steps to assess their condition—so you can replace them before your body pays the price.
» Get longer-lasting pain relief with custom orthotics
Custom vs. OTC Orthotics: Which Is Best for Your Foot Pain?
Orthotics are shoe inserts that ease foot pain, but not all are created equal. OTC orthotics are generic, while custom orthotics are tailored to your feet.
Here’s how they compare in durability, effectiveness, and wear over time.
Long-Term Effectiveness
- Custom Orthotics: Provide lasting relief for conditions like plantar fasciitis, heel pain, or flat feet by supporting your unique foot shape. They stay effective for years with proper care.
- OTC Orthotics: Offer short-term relief—a few months—but lose support as their soft cushioning flattens, leaving pain unresolved.
How Long Do They Last
- Custom Orthotics: Insoles with strong materials that resist wear, often lasting 12+ months.
- OTC Orthotics: Softer materials break down quickly (e.g., flattened arches), needing replacement every 6–9 months.
» Learn more about the best materials for orthotics
Wear Over Time
- Custom Orthotics: Distribute weight evenly to keep your feet aligned, preventing uneven wear and maintaining comfort.
- OTC Orthotics: Cause uneven wear (e.g., one side flattening) due to poor fit, leading to discomfort and frequent replacements.
Next Steps: Consider custom orthotics if you want lasting foot pain relief. Talk to a podiatrist or explore providers like Upstep to find the right fit for you.
How Long Do Orthotics Last? Custom vs. OTC Explained
Custom orthotics last 2–4 years thanks to strong, supportive materials—like durable foam and plastics—that resist flattening or cracking. Their tailored design fits your feet perfectly, reducing wear.
On the other hand, OTC orthotics last 6–12 months because softer foam materials flatten quickly, losing support and comfort.
Why Custom Orthotics Last Longer
Several factors make custom orthotics more durable:
- Stronger Materials: Unlike OTC’s soft foam, custom orthotics use firm materials that keep their shape for years.
- Tailored Fit: Designed for your foot shape, they distribute weight evenly, preventing uneven wear.
- Lifestyle Matters: Active people like runners, heavier individuals, or people with flat feet may wear out orthotics faster due to more pressure. Custom orthotics are better for these groups.
You should choose custom orthotics for durability and cost savings, especially for conditions like plantar fasciitis or flat feet. OTC orthotics may work for mild heel pain, but you'll need replace them more often—which may cost more.
Next Steps: Check your orthotics for signs of wear (e.g., flattened arches). For lasting relief, talk to a podiatrist about custom orthotics or explore trusted providers.
» Find out if you'll need to wear your orthotics for the rest of your life
When to Replace Your Orthotics: Key Signs to Watch For
Orthotics help ease foot pain, but they wear out over time, causing discomfort or new aches. Knowing when to replace them keeps your feet, knees, and back feeling great.
If you notice these signs, it’s time for a new pair:
- New or Worse Pain: Back, feet, hips, or knee pain when squatting.
- Less Support: Orthotics feel flat or less firm than before.
- Uneven Shoe Wear: Soles are wearing out unevenly due to poor support.
- Visible Wear: Flattened padding, cracks, or thin spots, especially in OTC orthotics.
How to Check for Wear
Regularly inspect your orthotics to catch issues early:
- OTC Orthotics: Check every 6 months, as their softer materials flatten faster.
- Custom Orthotics: Check yearly, as they’re more durable but still wear out.
- What to Look For: Press the arch for firmness, check for cracks, or note if cushioning feels thin.
Next Steps: You should replace your orthotics when you spot wear to prevent pain or worsening foot issues. Check more often if you’re active or notice uneven walking.
If your orthotics feel off, talk to a podiatrist about replacements. Custom orthotics may last longer than OTC for lasting relief!
» Check out the different types of custom orthotics
Should You Refurbish or Modify Orthotics Instead of Replacing Them?
You can often refurbish or modify orthotics to extend their life and maintain comfort, saving you money compared to full replacement.
Refurbishing or modifying your orthotics is a good idea when:
- The Main Structure Is Still Firm: If the base (or “core materials”) of your orthotics feels solid and doesn’t bend or crack easily, refurbishing can extend its life.
- The Top Cover Is Worn but the Base Is Intact: Replacing the outer top cover can restore comfort and support.
- You Need Small Tweaks for Comfort: Minor changes, like adding cushioning to replace slight thinning or adjusting the fit, can improve support as your foot condition changes.
- No Major Damage to the Base: If there’s only partial wear (e.g., a worn top cover or slight cushioning loss), refurbishing makes sense. But, if the base has “partial or complete loss of core integrity” (e.g., cracks or excessive flexibility), replace the orthotics.
» Find out what causes pain after wearing orthotics
When to Replace Your Orthotics Instead
Full replacement is necessary when:
- The Base Is Damaged: If the main structure bends too easily, has cracks, or no longer holds its shape, refurbishing won’t help.
- Severe Discomfort Persists: Even after modifications, ongoing pain could mean the orthotic isn’t right for you.
- Flat Cushioning: If the padding feels slightly flat but the base is solid, adding cushioning might be enough.
- Damaged Top Cover: Is it torn, thin, or smelly? A new top cover could fix this without replacing the whole orthotic.
» Read our in-depth comparison of OTC and custom orthotics
How Maintenance Affects Your Choice
Being proactive can delay the need for replacement and make refurbishing more effective.
Here's what you should do:
- Regular Cleaning: Keeps the top cover in good shape, reducing wear and preventing issues like odor or blisters.
- Rotating Pairs: If you have multiple orthotics, switching between them reduces strain on any one pair, keeping the base stronger for longer.
- Avoiding Damage: Keeping orthotics away from heat or sunlight prevents the base from breaking down, making refurbishing a viable option down the line.
What About the Break-In Period?
Even refurbished orthotics might need time to feel right. New or modified orthotics require a 1–2 week break-in period. Mild soreness is normal during this time, so don’t rush to replace them. But, if pain gets worse, it’s a sign the orthotic might not suit your needs
» Check out our guide on choosing the best insoles for your feet
Replace Wisely, Invest in Long-Term Relief
Knowing when to replace your orthotics isn’t just about avoiding discomfort—it’s about safeguarding your mobility. While OTC options may need swapping every 3–6 months, high-quality custom orthotics can last 1–3 years with proper care. But don’t wait for pain to become your warning sign.
If you’re tired of guessing or cycling through flimsy OTC inserts, consider upgrading to Upstep Custom Orthotics. Engineered from 3D-scanned molds of your feet, they offer personalized support that adapts to your gait and lifestyle—no more “one-size-fits-none” compromises.
Plus, their durable materials and expert tuning mean fewer replacements and more long-term relief. Take a free quiz for a free online assessment and step into a pain-free future. Your feet (and your body) will thank you.
Find Your Perfect Relief
Take our personalized quiz, and let us help you find the ideal insoles to keep you comfortable and on your feet all day.
Disclaimer: The information on this blog is for educational purposes only and is not a substitute for professional medical advice. Upstep does not provide medical diagnosis or treatment. While qualified podiatrists create our content, it's essential to consult with your healthcare provider for any foot or ankle concerns you may have.
