PioCreat, a global innovator in 3D printing technology, has launched a complete 3D printed insole solution that empowers clinics, orthotic labs, and footwear designers to produce custom insoles in just 35 minutes. Designed to simplify and digitalize the production process, this all-in-one system integrates 3D scanning, gait analysis, and multi-material 3D printing, making personalized foot support faster, more accurate, and more affordable than ever.
As the demand for custom orthotics continues to grow, many clinics and manufacturers are turning to additive manufacturing to enhance efficiency and patient outcomes. PioCreat’s solution brings every step — from foot data capture to final production — under one streamlined digital workflow, reducing turnaround times and ensuring consistent, high-quality results.
A Complete Workflow for 3D Printed Insoles
At the core of PioCreat’s system are two key devices: the IPX2 3D Printer and the FS A002 Plantar Scanner, both designed to meet the needs of clinical and industrial users.
The IPX2 3D Printer is an enclosed FDM system engineered for flexible materials such as TPU and TPE, which are ideal for producing durable, comfortable insoles. Equipped with dual extruders, the printer can produce two insole designs simultaneously — significantly increasing throughput. With printing speeds of up to 180 mm/s, a maximum temperature of 300°C, and layer thickness options ranging from 0.2 to 0.4 mm, clinics can now produce a pair of adult insoles in just 35 minutes.
Supporting this workflow, the FS A002 3D Foot Scanner captures precise plantar geometry in under 10 seconds using advanced laser scanning technology. The system generates accurate 3D models in STL and other mesh formats compatible with CAD/CAM software such as EasyLast, ShoeMaster, and Rhino.
More than just a scanner, the FS A002 also provides clinical insights — detecting foot deformities such as varus, valgus, and arch collapse. The data is automatically compiled into a detailed report, enabling clinicians and designers to make informed decisions for orthotic design, custom insoles, and specialized footwear.
From Scan to Step: A Fully Digital Workflow
The PioCreat Insole 3D Printing Workflow begins with gait analysis to identify pressure points and alignment issues. The FS A002 scanner then records accurate foot data, which is processed in CAD software to design a fully personalized insole tailored to the patient’s needs.
Using multi-material 3D printing, the IPX2 printer produces insoles that combine soft cushioning zones with rigid structural layers, ensuring both comfort and long-term support. Optional veneers or decorative finishes can be applied for added functionality or aesthetic appeal. Once printed, each insole requires minimal post-processing — ready for same-day or next-day delivery.
By integrating scanning, design, and production into a single ecosystem, PioCreat allows clinics and labs to reduce variability, improve precision, and scale production efficiently. The result is a faster, cleaner, and more sustainable approach to custom insole manufacturing.
Modernizing Orthotics with Additive Manufacturing
With its OEM-ready system, PioCreat’s 3D insole solution is built for scalability, making it ideal for clinics, hospitals, orthotic labs, and footwear manufacturers seeking to modernize their workflows. By replacing traditional manual fabrication with digital orthotics manufacturing, professionals can achieve faster turnaround, consistent quality, and better patient outcomes — all while reducing material waste.
PioCreat’s 3D printed insole solution represents the future of digital orthotics and custom footwear production — efficient, precise, and sustainable.
Learn more about PioCreat’s 3D Insole Printing Solutions at www.piocreat3d.com
