Custom orthopedic insoles 3D scanning: how does it work?

• In short

  Designing custom orthopedic insoles relies on capturing a foot impression, traditionally done with a foam box, a podoscope, or a dedicated 3D scanner. MyFit mobile 3D scanning makes this capture possible directly from a smartphone, with no specialized hardware. The resulting data — a 3D model and digital measurements — is then sent to the podiatrist or pedorthist, who designs the insole in CAD software before 3D printing. This approach makes remote foot capture easier, while remaining complementary to the professional’s clinical assessment.

Custom orthopedic insoles 3D scanning is gradually changing how podiatrists and pedorthists capture a patient’s foot. Rather than a physical mold, capture is done directly from a smartphone, before the data is sent to the professional who designs the insole. This article covers how this approach works, what tools exist, and what benefits it brings day to day.

What is a custom orthopedic insole?

An orthopedic insole — also called a foot orthosis — is a medical device placed inside the shoe to provide support and relief for the foot. It’s typically made from a thermoplastic material, shaped to the patient’s foot.

Manufacturing orthopedic insoles increasingly relies on technology-driven steps: 3D foot capture, computer-aided design (CAD), then 3D printing.

When should you wear orthopedic insoles?

Wearing orthopedic insoles is recommended in cases of pain in the foot, toes, ankle, knee, or lower back. A doctor or podiatrist may also prescribe them to correct posture, support the arch, or compensate for a leg length difference.

The advantages of 3D insoles and orthotics manufacturing

Healthcare professionals today have several tools available for capturing the foot impression needed to design a custom insole:

• A foam impression box: a box filled with deformable foam in which the patient places their foot, producing a negative mold used as the base for the insole.
• A podoscope: a mat or transparent plate that shows how body weight is distributed under the foot, usually as a color-coded map, to support the clinical assessment.
• A dedicated 3D scanner: specialized hardware that digitizes the foot impression, which then needs to connect to CAD software.
• A smartphone: a more recent solution, which makes 3D capture possible through a simple mobile app — this is the approach developed by MyFit Solutions.

Foam box, podoscope, dedicated scanner, smartphone: which tool should you choose?

Criteria	Foam impression box	Podoscope	Dedicated 3D scanner	Smartphone (MyFit mobile 3D scanning)
Required equipment	Box + foam	Dedicated mat or plate	Specialized scanner	None, just the smartphone camera
Mobility	Low, not easily portable	Low, fixed equipment	Varies by model	High, fits in a pocket
Consumables	Single-use foam	None	None	None
Data obtained	Physical mold	Pressure distribution	Digital 3D model	3D model + digital measurements
CAD integration	Requires additional digitization	Not applicable on its own	Yes, via dedicated connection	Yes, directly usable
Remote capability	No	No	Rarely	Possible

How does custom orthopedic insoles 3D scanning work?

• Step 1: foot capture

  The healthcare professional (podiatrist, pedorthist) performs the scan using a mobile app, relying on MyFit mobile photogrammetry. Measurement can be taken directly on the patient’s foot, or on the impression made in a foam box.

• Step 2: 3D reconstruction

  The captured images are used to reconstruct a digital 3D model of the foot, combined with digital measurements. This model can be viewed on a dedicated web platform and reused in the professional’s business tools.

• Step 3: insole design and printing

  The practitioner imports the 3D model into CAD (computer-aided design) software and makes the adjustments needed based on their clinical assessment. The final file is then sent to a 3D printer, which manufactures the custom insole in a matter of minutes, layer by layer.

What are the benefits of custom orthopedic insoles 3D scanning?

For healthcare professionals, this approach offers a solution that’s:

• simple: capture is done via a mobile app, with no costly dedicated scanner to buy;
• fast: a few seconds are enough to capture the foot in 3D;
• reliable: the digital measurements obtained are directly usable in CAD software;
• mobile: the scan can be performed anywhere — a podiatry clinic, a pharmacy, a patient’s home.

For patients, taking measurements becomes possible remotely, without prolonged physical contact with the professional.

Case study: a French insole manufacturer

MyFit Solutions’ technology has been adopted by a French insole specialist (orthopedic insoles, comfort insoles, heel cups), which relies on 3D scanning via smartphone to digitize the foot capture process for its customers.

This digitization brings several concrete benefits:

• fewer round trips with foam impression boxes to and from the patient;
• lower consumption of single-use material;
• shorter production time, thanks to a fast scan with results that are usable immediately;
• a simple, accessible technology for designing custom orthopedic insoles.

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