Discover design automation for orthotics: insoles with custom and local densities

June 23, 2022
We are introducing the automated workflow for insoles with custom and local densities.  


By integrating our cloud-based lattice generator with the digital design flow for custom-fit insoles, the finished product gains a whole new set of benefits. Besides the process being automated, easy to use, and easily integrated into existing workflows, the custom-fit insoles consist of personalized lattice structures based on the user’s needs. It translates into more comfort and a more satisfied customer.  


The custom-fit product is improved by adding lattices both in comfort and performance. The step-by-step creation process on the other hand is still as easy and intuitive. Watch the video below to discover the case and how easy and fast you can create reliable insoles with custom and local densities.

Let’s go through the end-to-end digital and automated workflow you just saw in the video. 

Creating the web-based platform

It begins with the product, designed by the client (for example an orthotic manufacturer or retailer), uploaded onto our parametrization software. The platform allows for the personalization of the product via a web-based interface (e.g., website, webshop, app). 

Customer experience & fitting

Next, the end-user experiences the fitting stage in a retail environment or a medical expert’s office. A 2D, 3D scan or pressure data is taken of the end-user’s feet and directly uploaded onto the scan-to-fit platform.  

Through a few intuitive steps, functional parameters are adjusted according to the end-users needs. This step is where the products become custom and personalized to the customer or patient based on data input.  

It results in a perfectly fitted insole with custom and local densities thanks to the lattice structures. 

Seamless production

The automatically generated manufacturing file is sent to a production facility where the parts are 3D-printed. Though, you are not limited to additive manufacturing. The Twikit technology is also compatible with CNC machining and other production methods.  


Finally, the insoles are packaged and shipped to the end-user, retailer, CPO, or clinic. They can enjoy the comfort of meticulously fitting insoles with increased comfort thanks to the lattice structures giving excellent support in all the right places.  


Why choose insoles with lattice structures?

Sports gear and orthotic devices, such as shoes and soles, have opened the doors to lattice structures in the consumer market. It replaces foam as a buffer or protection material. That is why it can be used for many different products with protection and energy absorption as primary purposes, such as helmets and pads.  

But why do manufacturers choose 3D-printed lattices instead of traditional foam? Because it eliminates certain production limitations and enables a high-performance design. Manufacturing is made more efficient and the finished product is of the highest quality.  

From more than 50% to 2% of manufacturing waste

As a big plus, it reduces waste significantly during the manufacturing process. Conventional EVA material (an elastomeric polymer with a ‘rubber-like’ softness) creates 20% waste during the cutting and an astounding 50% waste during the CNC milling process. It is a massive amount of material thrown away if you know that 3D-printing insoles result in only 2% waste from start to finish. 

And not to forget: digital manufacturing technology doubles the durability of insoles.