How does 3D printing custom insoles work?
Replicating an insole happens in three phases: scanning, modeling, and printing. Each phase has its own role, and together they ensure that the shape of your old insole is captured as accurately as possible in the new one.
Scanning: capturing the shape of your insole
A 3D scanner measures the surface of your insole, including the curve under your arch and the elevation at your heel. The result is a digital copy of the exact shape. Curious about the technical side? Inhow a 3D scanner worksyou can read about the differences between the various types of scanners.
Modeling: from 3D scan to printable file
A raw scan isn't a printable file yet. It contains holes and noise, and the bottom needs to be flat enough to sit properly in your shoe. That’s why the scan is converted into a clean 3D model. This is the same step as inCAD modeling, only here you aren't starting with an idea, but with an existing object.
3D printing: a new insole, layer by layer
Finally, a 3D printer prints the insole layer by layer using flexible material. This is no longer an experimental technique: orthopedic companies also print insoles these days, although they usually measure them from scratch rather than replicating an existing insole.
How to have your insoles replicated in 5 steps
- Check if your insoles are still usable. A scan copies everything, including wear and tear. Read below to see what to look out for.
- Request a quote. Specify which insoles you need and how many pairs you want.
- Send in your insoles. A photo isn't enough: for an accurate scan, the actual insole needs to be placed under the scanner. Pack them securely so they don't bend during transit.
- Your insoles are scanned and modeled. The scan is cleaned up into a printable 3D model of your left and right insole.
- Your new pair is printed and shipped. Expect the entire process to take 5 to 10 business days.
When can your orthotic insoles still be replicated?
This is the point most people overlook: a scan copies exactly what is there. If your insole is worn flat, you will get a neatly printed, worn-flat insole back. The printer doesn't know what your insole used to look like.
Your insole can usually still be replicated if:
- the arch support is still clearly visible and tangible;
- the insole is intact, without cracks, breaks, or pieces coming loose;
- the heel still has its original shape and hasn't collapsed or tilted.
In doubt? Place your old insole next to a photo of it when it was new, if you have one. If you see little difference, you're good to go. If the arch is almost gone, replicating it won't do you much good.
So don't wait until your insoles are worn out. The best time to have them replicated is while they still feel great. That way, you're copying a shape you already know works for you.
What material are 3D-printed orthotic insoles made of?
Printed insoles are made of TPU 90A. TPU is a flexible plastic that bends and then springs back to its original shape. That makes it suitable for something you stand and walk on all day.
The 90A refers to the hardness. The higher the number, the firmer the material. At 90A, the insole feels firm but still gives when you bend it. Softer isn't always better: an insole that is too soft will compress and lose the shape you want to maintain. You can read more about the properties inTPU filament: everything you need to know.
Good to know: a print copies the shape, not the construction. Many orthotic insoles from a podiatrist consist of multiple layers, such as a foam core with a fabric top layer. Your printed insole is a single piece of TPU. It may therefore feel different than what you're used to, even if the shape is the same.
A benefit of TPU: it barely absorbs moisture. You can rinse a sweaty insole with lukewarm water and let it air dry.
How much does it cost to have orthotic insoles 3D printed?
Most pairs cost between €100 and €200. This price covers the entire process: scanning, modeling, and printing both your left and right insoles.
Where you land within that range mainly depends on two things. The size of the insole determines how much material and print time are required. And the more complex the shape, the more work it takes to clean up the scan.
A flat insole with a slight arch will be on the lower end, while a highly contoured insole with a deep heel cup will be on the higher end. If you want to know how 3D printing prices are generally determined, read how much does 3D printing cost.
Allow 5 to 10 working days for turnaround. Don't leave it until the last minute, especially if you only have one pair. Without insoles in your shoes, you'll be going without support for a couple of weeks.
Don't expect reimbursement from your health insurance. A 3D-printed copy is not a medical device fitted by a healthcare professional. Check your policy if you're in doubt.
A second pair is more useful than you think
Not everyone who gets their insoles copied has worn-out ones. A growing number of people just want an extra pair. There are good reasons for that.
The first is rotation. Insoles that stay in the same shoes every day don't get a chance to dry out. That’s why podiatrists themselves call itgreat to have a second pairso your insoles can air out.
The second is convenience. With one pair in your work shoes and another in your sneakers, you don't have to swap them every morning. And if you forget them once, you won't be stuck without them all day.
The third is timing. With daily use, insoleslast about a year. If you get them copied while they’re still in good condition, you’re capturing a shape that still works for you. The digital model can be reprinted later without you having to send your insoles away again.
When 3D printing isn't the best choice
Copying works well if you're happy with your current insoles and just want more of the same. It doesn't replace a consultation. A copy replicates the shape, but it doesn't assess whether that shape still suits your feet.
In these situations, it's better to see your podiatrist first:
- you have new or different complaints than when you first got the insoles;
- your insoles haven't felt comfortable for a while;
- they are for a child, as children's feet grow and change quickly;
- you wear them in safety shoes, which often have specific requirements for the combination of shoe and insole.
If you want to be absolutely sure your insole is a perfect fit for your foot, getting them professionally fitted again is the safest choice. If you want a reliable copy of an insole that already works well for you, 3D printing is a fast and affordable option.
Conclusion
3D printing custom insoles comes down to one question: is your current insole a good base? If so, you'll have a new pair with the exact same shape within two weeks.
And after reading this, you might realize you have something else that's worn out and no longer available for purchase: a small cover, a clip, or a holder. The same principle applies to those. Inhaving a spare part madeyou can see how that works. Not sure if your insoles can be replicated?Request a quoteand describe what they look like, and we'll give you an honest answer before you send anything in.
Frequently asked questions about 3D-printed insoles
Is a 3D-printed insole the same as one from a podiatrist?
The shape is the same, as it's copied from your own insole. The material and construction differ: a printed insole is a single piece of TPU, without separate layers or a fabric top cover. It also doesn't include a new assessment or professional advice.
Can I send a photo instead of my insoles?
No. A photo doesn't show the height and curvature of an insole, which are exactly what determine how it feels. To get a good copy, the insole itself needs to be scanned. You can read why a photo often falls short infrom image to 3D print.
Does my health insurance cover 3D-printed insoles?
It's unlikely. Reimbursement usually only applies to insoles fitted by a healthcare professional. Check your policy if you want to be sure.
Can I wash a 3D-printed insole?
Yes, by hand. TPU barely absorbs any water. Rinse the insole with lukewarm water, use a little mild soap if necessary, and let it air dry. Do not place it on a radiator.
Will the printed insoles fit in all my shoes?
They will fit in the same shoes as your original insoles because the shape is identical. If your old insole only fit in your hiking boots, the same applies to the copy.
Can I have my child's insoles replicated?
We advise against this without consulting a podiatrist. Children's feet change quickly, meaning a copy of an old insole will likely no longer fit.