Custom Insole Module

The clinical problem it targets

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 module is in development; we publish no measured clinical results for it.

The planned workflow

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.

Intended measurements and output

The intended output is an STL file that can go to the clinic's printer or to a partner manufacturing centre. For clinics milling blanks, the CNC line is assessed separately and is outside this module's scope.

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.

Because the module is still in development we publish no clinical results, fit rates or patient counts for the insole line. We build the flow together with waitlist clinics on their real case mix, and which material suits which case group is shaped by their protocol.