Industry
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Biomedical
What We Did
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3D Scanning
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Reverse Engineering
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Exporting data: STL to STEP
Project Details
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Insole Reverse Engineering
Precision modelling for medical applications and additive manufacturing -
3D Scanning Accuracy: ± 0.05 mm
Final CAD Accuracy: ± 0.1 mm (Average). Local deviations may vary depending on geometry and feature accessibility
This project focused on the digital reconstruction and optimisation of an orthopaedic insole, developed for operators and companies working within the biomedical and orthotics sector.
The process began with high-resolution 3D scanning of an existing insole to accurately capture its anatomical geometry and functional contours. The scan data was used as a geometric reference to rebuild a clean and fully editable CAD model, ensuring precise control over curvature, thickness distribution, and critical support areas. Rather than relying directly on mesh data, the geometry was reconstructed using a parametric approach. This enables consistent modification, patient-specific adaptation, and repeatability across production workflows, key requirements in clinical and manufacturing environments.
Following the CAD phase, the model was further developed within a dedicated Design for Additive Manufacturing (DfAM) environment. Here, the insole was optimised for lightweight performance through controlled structural strategies, preparing it for efficient additive production.
The final component was manufactured using Multi Jet Fusion (MJF) technology in flexible TPU material, achieving a balance between mechanical support, comfort, and durability. The result is a production-ready orthopaedic device that integrates digital precision with advanced manufacturing capabilities.
Key aspects:
- High-resolution 3D scanning of anatomical geometry
- Parametric CAD reconstruction for full editability
- DfAM optimisation for weight reduction and performance
- Additive manufacturing via MJF technology
- Flexible TPU material for functional orthopaedic use
