Custom Insole Module

Custom insoles run into two difficulties at once. The first is the impression: a foam box or plaster negative changes with the position the foot is pressed in, and that difference yields two different insoles for the same patient. The second is the record: nothing writes down how much support a hand-shaped insole gave in which region, so six months later the decision starts from scratch.

The module targets both points: keeping the scan as a digital record and writing regional interventions down as parameters. The desktop engine and workflow are ready, with field validation ongoing in pilot clinics.

In the designed flow the foot scan is imported and aligned to the plantar plane. The clinician marks the metatarsal heads, medial arch and heel; posting height and shell thickness are set per region. The surface can then be raised or lowered locally with a brush tool.

In the final step the clinician approves the stiffness distribution and the material choice. That decision is not handed to the software: the same geometry printed in rigid resin and printed in TPU is a different device. The production file is exported after approval.

On the manufacturing side, the module produces both solid/lattice STL/OBJ files for 3D printers and positive surface data for CNC carvers milling EVA blanks. Clinics can select additive 3D printing or CNC milling output depending on their shop infrastructure.

On the measurement side we plan to write scan-derived values such as foot length, width and arch height into the case file, so the next insole starts from a recorded measurement rather than a remembered impression. The workflow is being validated across real clinical cases with pilot partner clinics.