Gradually, 3D printing penetrates into all areas of our life. In addition to the usual directions, such as prototyping, creating architectural models, parts, master models, household items, etc., 3D printers are used for other purposes. The production of footwear using additive technologies is not a new direction, but at the moment it is not widespread. There are companies that use 3D printers as an additional element to the main production - the creation of accessories, jewelry, and shoe design elements. Some of them make shoes on a 3D printer on a turnkey basis from insole to sole =)

Raise3D's customers include two companies that use 3D printers to make specialized sneakers and smart insoles. Let's tell their stories.

Creation of specialized sports shoes on Raise3D 3D printers

At 25, Oliver Brossmann is already an entrepreneur and designer of unique sports shoes. As a child, he, like many boys, dreamed of becoming a professional football player. But after undergoing knee surgery in high school, I had to say goodbye to the dream. During his recovery period, Brossmann began exploring approaches to running and exercise with minimal stress on the joints and knees. At Brossmann College, in addition to basic subjects, he attended a couple of computer science and prototyping classes. With the goal of bringing his business idea to life and putting this knowledge into practice, Oliver left college and started working on his own startup, Prevolve. This project was developed from scratch with a small investment from a private investor. Oliver's startup at the moment is Oliver himself, a couple of part-time employees and his sister, who helps with work moments.

After 3 years, Brossmann officially launched his company's first product, BioRunners. The shoe was created on the BioFusion platform, developed by Oliver for 3D printing special sports shoes. Combined with a professional foot scanner that produces accurate scans, the product just got better and better with every iteration.

Prevolve shoes are printed with TPU, a material that is durable and abrasion resistant. In the Prevolve online store, customers can choose the right color, shock absorber and tread thickness - for trail or street running.

“Each pair of shoes is designed for a specific foot and, accordingly, the shape of each is unique. I am still thinking about upgrading the design to make the shoe more attractive and performance-enhancing, ”says Oliver. Prevolve shoes take between 20 and 30 hours to 3D print, depending on size. Oliver uses Raise3D printers, which are optimally sized for sneakers.

Buyers of Prevolve shoes are athletes, professionals and amateurs, as well as people with special feet (different foot sizes, flat feet, etc.). 3D printed shoes are the cheapest and fastest to manufacture compared to orthopedic shoes. , custom-made in the traditional way.

3D printing of smart insoles on Raise3D N2

Dr. Roy Cheng of Gait & Motion Analysis Lab is the creator of smart smart insoles that are 3D printed. Roy himself is fond of jogging and wanted to buy smart insoles for himself, but the expensive market value made him think about implementing this project himself.

Roy specializes in running biomechanics, the effectiveness of prophylactic devices for athletes, training in rehabilitation and injury prevention, and has received major research grants for his developments.

Both creating a custom insole and smart insoles using traditional methods is a complex and expensive process, and the target audience is very narrow.

Disadvantages of the traditional method that Roy Cheng and his team used in the beginning:

1. High production cost;
2. Only large production runs for injection molds;
3. Inaccurate result when produced by hand;
4. The term of use is 1 year.

• casting molds from foam, silicone or plaster (often by hand);
• thermoforming the insole according to the footprint;
• correction of the insole and completion of work.

1. Reduce production time by 64.29%
2. Reduce production cost by 99.5%
3. Develop accurate and perfect models.

The equipment list includes: computer, scanner, printer instead of thermoforming and grinding machine.

Smart insoles are made up of electronic sensors and a thermoplastic base. The manufacturing process can be divided into three main stages:

1. Foot scan;
2. Insole modeling and gauge placement / design;
3. Electronics printing / installation.

Using a rendered model and 3D printing, Roy maximized the protection of the electronics located on the insole. This was done by correctly placing all the components on the insole and by controlling the firmness of the insole by choosing the right filament and the percentage of filling the model when printing. All electronic components are placed between layers.

By using 3D printing, Roy's company was able to eliminate most of the insole manufacturing processes. Raise3D N2 can build a finished product inside and out with an individual insole shape and a specific arrangement of elements, and will automatically leave space for the circuit. After installing the circuits, the printer completely covers the electronics, printing the top additional layers.

By automating this process, labor costs, equipment costs and lead times are reduced.
Most importantly, Raise3D allows you to customize your insole printing and layout in a single print session. As a result, the cost of the insole is significantly reduced, the manufacturing time is reduced from 2 weeks to 5 days (or less).

Tsvetnoy Mir team