Milling for digital footwear solutions

Using a digital design file, we 3D-print orthopaedic footwear products. You determine the design, the adjustments, the fit and the functional choices. We translate that digital design into a physical product. 

This service is intended for orthopaedic shoemakers, shoemaking workshops and manufacturers of orthopaedic shoes. We are the external production partner that transforms your design into a last, insert or other bespoke component. We are not a separate supplier, but an extension of your workshop. As well as 3D printing, we also offer milling services. We work with you to determine the most suitable production technique for each application. 

Discuss the possibilities
3D scanning model for custom orthopaedics

Which footwear technology What products can we print? 

We 3D-print a wide range of products for orthopaedic footwear technology. These include orthopaedic lasts, last models for bespoke shoes, left and right lasts based on individual foot data, orthopaedic inserts, heel lifts, compensations for leg length discrepancies, support for the longitudinal or transverse arch, and supination or pronation corrections. 

We manufacture both individual items and pairs. Do you have an unusual shape or a specific application? Please get in touch with us. Some components are better suited to milling than to 3D printing. We always advise on which production method best suits your design. 

Milling table Image

From foot scan to printed last 

The process can be summarised in ten steps: 

  1. You digitally capture the shape of the foot. 
  2. This can be achieved using a 3D foot scan, a 2D scan, a pressure measurement or a scanned blueprint. 
  3. You import the measurement data into your design software. 
  4. You will model the last and make the necessary corrections and fit adjustments. 
  5. You provide us with the digital design file. 
  6. We carry out a technical check on the file to ensure it is suitable for production. 
  7. We prepare the file for the 3D printer. 
  8. The last or insert is printed from the chosen material. 
  9. We check the shape, dimensions and finish. 
  10. The product is sent to you, ready for further processing in the shoe-making workshop. 

You determine the shape, the corrections and the functional properties. We assess the file from a technical perspective, not from a medical or treatment-related point of view. The design you provide guides the production process, and we do not make any adjustments without consulting you first. For repeat orders, we print again using the same digital file. 

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Printing orthopaedic aids 

Insoles are used to distribute pressure, influence foot position or compensate for a leg length discrepancy. In your design software, you specify, amongst other things, the shape, position, thickness and correction. We manufacture the insole according to the geometry you provide. 

We supply accessories separately, in pairs or as part of a larger order. Depending on the product, you will need to carry out any finishing work yourself, such as lining or gluing them into the shoe. 

Materials for 3D-printed footwear solutions 

For lasts, we print using a wood-like filament. This produces a lightweight, printed shell which is filled with PU foam to provide the necessary strength. You can further process these by sanding, gluing or stapling. For eco-friendly lasts, we use a strong, lightweight and easy-to-sand filament. 

For fitting templates, we print using a flexible, PETG-based material. This allows you to quickly and accurately validate the fit before proceeding to final production. 

For supplements and insoles, we print using TPU-based materials that combine multiple densities within a single product. This ensures targeted pressure distribution, a good fit and a washable, skin-friendly finish. These materials can be easily sanded to achieve a precise fit on the last. 

The most suitable material depends on the product, its intended use and the further processing required in your workshop. We’d be happy to advise you on this for each specific application. Alternative materials can always be discussed in consultation. 

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3D printed commemorative statues

The benefits of digitally printed footwear solutions 

Your digital design is translated directly into production, with fewer handover stages between measurement, design and production. Corrections and fit adjustments are embedded in the file. This ensures more consistent dimensions for repeat orders. 

Other practical benefits: 

  • Less physical storage of lasts and models is required. 
  • Digital files are stored and can be reused at a later date. 
  • An existing design can be adapted for follow-up treatment, rather than starting from scratch. 
  • Less manual assembly and adjustment required, depending on the product. 
  • Extra production capacity without having to invest in a 3D printer or milling machine yourself. 
  • Reduced reliance on a single person manually manufacturing the product. 
  • This leaves you with more time for design, fitting and patient care. 

Outsourcing 3D printing for footwear technology 

We act as an extension of your shoe-making workshop. This applies to both one-off commissions and regular production runs. We can scale up to meet demand for larger quantities or during temporary peaks in workload. We store digital design files so that you do not need to resubmit them with every repeat order. You can track the status of your order via the order portal. 

Would you like to know what this means for your minimum order quantity, maximum sizes, average lead time or a rush order? Please get in touch. We’ll then work with you to see what’s feasible for your situation. 

Part of a digital footwear workflow 

3D printing ties in seamlessly with the entire digital process within footwear technology: from foot scanning and CAD design to production and further processing in the workshop. You use the same software for modelling lasts, drawing insoles and generating fitting templates. 

You submit your design file via our order portal. We manage new versions, amendments and repeat orders digitally, so you’ll never lose a design. Are you new to this way of working? We provide support with the implementation of scanners, software and digital production. Would you like to know more about our scanners, software, 3D printers, accessories or fitting sheets? Take a look at the relevant pages. 

Technical support for the printing process 

Where we do contribute ideas: 

  • Check whether your file is technically suitable for production. 
  • Advice on milling or 3D printing. 
  • Advice on materials and density. 
  • Answering questions about file types and submission. 
  • Identifying technical issues in a digital design. 
  • Supporting the integration between design software and production. 
  • Assisting with your first orders. 
  • Discussing specialised products or non-standard applications. 

What we do not provide: 

  • The treatment. 
  • The necessary correction. 
  • Assessment of foot posture. 
  • The fit. 
  • Designing or modifying the last without your instructions. 
  • Assessment of the end product on the patient. 

If a file is technically impossible to produce, we will contact you to discuss the problem and a possible solution. 

Want to have orthopaedic footwear products 3D-printed? 

We 3D-print lasts, inserts and other bespoke components based on your digital design. Precise, repeatable and ready for further processing in your workshop. 

Are you a new customer? Please contact us to arrange an introductory meeting or technical consultation. Are you already working with us? Submit your design directly via the order portal. Do you have a special design, material or application? Please discuss this with us in advance. 

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Daniel van Krevel

What can we
help you with?

podiatry physiomed
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Design and produce orthotics fully digitally. Work with fixed quality and a tight workflow from scan to 3D print.

Orthopaedic shoe technology
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Digitise lasts and fitting models with 3D printing technology. Reduce your lead time and work with consistent precision.

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What our customers have to say

Guido Shoes

(5)

"Since working with Shapemakers and scanning body parts instead of using plaster, our process has become on average a week faster. The... fit is noticeably better and more accurate, and in case of questions, Shapemakers is always readily available and willing to help. "

OIM Orthopaedics

(5)

"3D scanning allows us at OIM Orthopaedics to work faster, more efficiently and location-independently. With Shapemakers as a permanent partner in the... scanning and milling of orthopaedic instruments, we are taking a big step forward in quality and innovation. "

B&C Custom Bracing

(5)

"With B&C Custom Bracing's 3D printed knee brace, we are demonstrating how digital workflows make customisation scalable. Thanks to collaboration with... Shapemakers and Shapeshift 3D, we process a knee scan into a perfectly fitting design within minutes, without compromising on comfort, protection and freedom of movement. " "

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Talking opportunities

Would you like to know more about our options in podiatry? Then feel free to contact us.

Already a customer, and already have an account? Then you can access our customer-friendly order portal. Here you can order yourself and keep an eye on the order status.

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info@orthoshapes.nl
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