Callus Foot Pads: Felt, Foam or Gel, What is the Difference?

So what is the difference between foam, felt and reusable gel callus foot pads? The typical callus pad is typically manufactured from one of three materials. These materials are medical grade felt, foam and gel. All of them will off load a painful foot callus to decrease the pain and help prevent them from returning.

Lets discuss the felt callus pad. It is the most common material used in foot pads. The most common material for a  callus pad is a felt. Medical grade felt is produced from a blend of cotton and Rayon. The cotton/Rayon padding is compressed in to sheets called felt. The advantages of felt callus pads are that the material breathes with allows sweat to wick away from the body. Also these callus protectors are easily cut to form a more custom fit. Felt is denser than foam callus pads and will hold its thickness longer. Felt also allows the user to peel off the material to make the pad thinner. Felt callus pads usually come in 1/8" or 1/4" thickness and have an adhesive backing to all the pad to stick to the skin or into the shoe.

The second most common callus foot cushion material is a foam callus pad. Foam is produced from petrochemicals in to sheets that are cut to form the foot pad. Foam does not breathe as much as felt does.  Foam callus foot pads are more of a spongy and flexible than the felt.  A foam callus pad will compress faster than the felt one. Some patients prefer the foam due to its spongy feel. Just like the felt callus foot pads, the foam one also are produced in 1/8" or 1/4" thickness and have an adhesive backing.

Gel callus pads are the newest type to be produced. The advantages of the gel callus pad is how long it lasts. It can be used over and over again and it will not compress. The bottom of the gel foot cushion is sticky. The gel is not as spongy and soft as either the felt or foam material. Gel callus pads also cost more to produce. 

Teri Green

Atlas Biomechanics

Atlas Biomechanics: We are a woman owned sports medical manufacturer of Foot Pads, Heel Lifts and Heat Moldable Orthotics.