Wow. Sorry to hear that.
I had no discomfort AT ALL with my orthotics and they fit me like a glove when they came in. There was no "break in period." I had an adjustment done (after I switched to a narrower shoe and under the eyes of my PT/chiro/doc who watched me on a bike). They made marks on my old orthotics and sent them back to the lab and new ones were cast. I got it back in two weeks and had no other issues.
EDIT: Mine were CF, not plastic.



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