Orthotic Insole Design and Manufacturing

The knowledge offer focuses on the manufacture of customised or standardised orthotic insoles. The team of podiatrists at UMH can provide advice and assessment on their manufacture, combining a practical approach with research-based knowledge in the field. Manufacturing methods may range from manual, traditional production to 3D printing. The technology can be applied to the treatment of specific injuries, as well as to sports insoles, paediatric correction and special needs.

The knowledge offered may be of interest to companies involved in the design and manufacture of orthotic insoles. These companies can contact us to apply this knowledge from a podiatric perspective, both to the manufacture and assessment of their products.

In this way, companies involved in the manufacture of orthotic insoles, both in production and design, can offer their customers medical devices based on scientific evidence. The knowledge can be applied in different areas, including companies seeking to innovate in new technologies for the design of customised orthotic insoles, such as 3D printing, as well as processes involving foot scanning for moulding, and advice to companies involved in designing orthotic insoles using software applications. Advice and design services can also be provided for non-specific orthotic insoles intended for patients with common conditions, such as high-risk patients, sports footwear applications, or companies developing software products related to these applications.

Foot orthoses play a very important role in the treatment of foot disorders. They are the main tool used by podiatrists to treat the musculoskeletal conditions of patients seen in daily clinical practice. There are many categories of orthotic insoles, ranging from “off-the-shelf” products ready for use to handmade or customised solutions. Personalised treatments are designed according to the shape and size of the foot and the patient’s condition. It is therefore essential to incorporate scientific evidence into the manufacture and design of orthotic insoles in order to ensure high-quality products that meet demand while safeguarding foot health.

As specialists in the foot, podiatrists are ideally placed to bring together all the expertise required for the manufacture, assessment and design of orthotic insoles, including healthcare, paediatric podiatry, biomechanics and footwear. Applying this knowledge could improve manufacturing processes, ensure that resulting products protect foot health, and adapt biomechanical or medical requirements to the needs of different sectors.

The University’s research team has conducted research and provided training in this field over the years through different scientific studies and population-based analyses. The team has also delivered training courses on orthotic insole design and manufacturing, both internally at the University (Degree in Podiatry and Nanomaster’s Degree) and externally through professional associations, private courses and master’s programmes.

The introduction of 3D printing for the design and manufacture of orthopaedic treatments in the field of podiatry is expected to bring improvements to the profession and represents a new future trend. It has the potential to improve the manufacturing process. In recent years, many clinical podiatrists have been motivated to adopt this new approach for manufacturing treatments for their patients, as the technique offers several advantages, including reduced costs, lower labour requirements, shorter manufacturing times, more efficient use of the podiatrist’s time, improved cleanliness and greater working convenience, as well as long-term cost savings. Clinical experience among professionals and patients appears to have been very positive, with good results. Improving these techniques remains a daily challenge due to their relatively recent introduction, making it essential to combine scientific knowledge with traditional podiatric expertise.

At the same time, investing in new manufacturing methods can reduce both economic and environmental costs associated with materials and production.

Fully operational. The research team has extensive experience in undergraduate and postgraduate education, as well as in knowledge transfer through professional associations. 3D design and manufacturing technology is already being successfully applied in clinical settings and is ready for transfer to industry.

• Healthcare (Podiatry and Orthopaedics).
• Additive Manufacturing and 3D Printing Industry.
• Sports Sector and Footwear Biomechanics.
• Medical Software Development.

Paloma López Ros – Department of Behavioural and Health Sciences