White Paper

Mechanical Performance Analysis of 3D Printed and Traditionally Manufactured Rigid Insole Shells

This study investigates material properties and manufacturing methods for custom orthotic insoles: Formlabs Fuse 1+ 30W and Nylon 11 Powder, HP 3D High Reusability PA 11, and traditionally manufactured polypropylene.

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Table of Contents

  • Background
  • Sample Sourcing
  • Results
  • Discussion
  • Conclusion
  • Limitations
  • Get Started With 3D Printed Insoles


A rigid insole is an orthotic device that is used to help the wearer correct abnormal foot posture or provide additional support. If not addressed, poor foot posture can cause foot, ankle, knee, or back pain, as well as more permanent issues. Customized insoles can be prescribed or recommended to a patient by a podiatrist, or another medical professional with proficiency in biomechanics. Generic versions can be purchased over the counter to address common self- diagnosable conditions.

Sample Sourcing

Three samples were used for each test; one from Formlabs, one from HP, and one traditionally manufactured from polypropylene. Details on each sample can be found in the table below. Each sample was created using the same model provided to us by Gespodo and shares the same dimensions (2 mm thickness from center to edge). That model can be found here.

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