What equipment is required for making orthotic insoles and what is the production process?

English Literal Translation of Orthotic Insole Production Equipment and Process

When people suffer from flat feet, high arches, arch varus, arch valgus and other foot problems, most people choose to use orthotic insoles to achieve correction purposes.

So what equipment is needed in the production process of orthotic insoles? What are the specific processes?

1. Plantar 3D Scanner

In the past, insole data was measured by traditional manual methods. However, manual measurement is very time-consuming. Meanwhile, measurement data is prone to inaccuracy due to human errors, with low measurement precision. This will lead to poor using effect of finished insoles, making it difficult for insoles to fully fit the soles of feet and hard to meet correction requirements.

With the introduction of plantar 3D scanners, foot measurement has become a very simple step.

For example, the 3DOE plantar 3D scanner measures foot soles based on laser principles, with a precision within 0.5mm, which fully meets the production requirements of orthotic insoles. Data collected by this scanner can be used to produce insoles that fit foot soles completely. Besides, the measurement takes little time and can be finished in about 20 seconds generally.

Measurement with plantar 3D scanners can not only save time, but also reduce labor costs. Especially for mass measurement work, this automatic measurement method has huge advantages.

2. Plantar Pressure Plate

The plantar pressure plate is a device that adopts pressure sensors to sense the pressure distribution of each part of the sole and relevant gait data when people are in static or walking states.

With the measured plantar pressure data and gait data, designers can better understand the foot stress conditions of users. Especially for users with foot deformities such as flat feet, high arches, foot varus and foot valgus, these plantar pressure and gait data can provide more scientific and objective data references for designers, helping them design insoles with correction effects.

Certainly, if customers only need ordinary customized insoles without functional correction effects, the plantar pressure plate is not necessary, and the equipment selection depends on actual situations.

The production cost will increase if this equipment is adopted.

3. Insole Design Software

Custom insoles require personalized design, namely targeted design according to individual actual foot conditions.

The whole design process needs to apply professional insole design software.

Designers will import STL format plantar 3D data and plantar pressure data into the software, and then carry out targeted design to make finished insoles meet customers' demands.

4. 3D Printer or Insole Engraving Machine

Common materials applicable to 3D printers include PLA, TPU soft glue, resin, nylon and so on.

3D printer belongs to additive manufacturing, which shapes products by stacking materials layer by layer.

The insole engraving machine belongs to subtractive processing. It shapes complete EVA and PU materials by cutting heads and removes redundant materials with cutting heads.

Common materials applicable to engraving machines include EVA foam, PU and high-elasticity insole plates.

Engraving machines are more suitable for mass production, while 3D printers have lower single-piece production costs.

After completing insole design, designers export design files from the insole design software, then transmit the files to 3D printers or insole engraving machines via USB flash drives to finish insole production.

5. Grinding Machine and Laminating Tools

After the preliminary production of insoles, grinding and surface laminating processes are required to improve the appearance of finished insoles.