1. Footprints Magazine 16
RESEARCH & TECHNOLOGY
I
n the Podiatry world 3D technol-
ogy is nothing new. The basic
technology has been around
for some 20 years, used for the
production of insoles and orthot-
ics. But with the advancement of
3D software the net is spreading.
Bespoke shoe manufacture and
3D foot scanning in retail stores
and on personal devices are here
– and Podiatrists need to stay en-
gaged with the progress.
As the 3D bandwagon balloons,
websites like 3dprintingindustry.
com and 3ders.org are providing
daily news on technology, design-
ers and the latest objects being
printed from shoes to cars, so it is
worth signing up for news. Mon-
ey is also being heavily invested
in development.
3D Printing Industry news recently reported that $1.25
million in seed funding lead by Silicon Valley – based Khosla
Ventures, will provide United States based company Feetz
the opportunity to provide custom shoes for the individual.
Feetz CEO and Founder Lucy Beard said in a media
statement: “Today, we wear a shoe that’s been made
and sized to fit anyone. I’m excited to bring a new reality
to market by offering 7-plus billion shoe sizes–one for
everyone in the world. Our shoes are not only custom fit but
can be customized so that no two pairs are ever the same.”
Customers will be able to create their shoes through the
Feetz app, which takes only minutes to create the 3D scan
and needs only one piece of paper and three photos of
each foot. The customer then chooses a design and col-
our and the tailor-made shoes will be delivered in days.
Also bringing 3D technology to retail is Swedish company
Volumental which recently launched their 3D scanning
service, designed to ensure the customer never has to try
on a range of shoe sizes again. The feet are scanned,
the information stored and the right shoe selected at any
time. The Scarosso store in Frankfurt will be the first to trial
this new service starting around October.
But Feetz and Volumental are just two of many companies
moving at a rapid pace to a digital experience or to
create custom made shoes. United Nude and 3D Systems
also showed their prowess at the 2015 Milan Fashion
Week in May where some vibrant, outlandish designs
were featured. From a podiatrists point of view, these
designs would not be considered very good for the feet
(see Zaha Hadid’s “Flames” photo).
The price tag for individual products is also yet to be
officially finalised but it is high, with footwear company
Strvct Shoe selling for around $900 a pair. For Podiatry
products the development and cost is ongoing. Member
Dominic Hogan recently witnessed a 3D product
demonstration with a high price tag for products but saw
the long-term potential.
“I was recently able to watch a demonstration of a 3D
scanner at the national podiatry conference on the Gold
Coast, where custom made orthoses and shoes could
be made in Australia with an estimated cost of $1,000.
Although research will be required and undoubtedly
occur, I anticipate this area will expand with customised
orthoses and shoes made to complement each other, and
more importantly the patient,” he said.
"Flames" 3D fashion shoes by Zaha Hadid
It’s a 3D world

2. Footprints Magazine 17
RESEARCH & TECHNOLOGY
“This advancement has the
potential to be especially
beneficial for high risk cli-
ents, or patients with partial
amputations, where the or-
thoses and prosthesis can be
custom made to the patient’s
needs, and fit perfectly into
the shoe made from the
same image.“
The 3D printing of shoes
sounds easy but apparently
this is not the case, especially
for long lasting, performance
shoes like runners which you
do not want falling apart in
the middle of a race.
One 3ders news blog reports that Nike and New Balance
are using 3D printing for some designs but only for parts
of the shoes such as Nike for a football cleat and New
Balance for a spike cleat on a track shoe that is supposed
to enhance performance. Overall expanding the materials
that can be used in 3D technology needs more work as
currently this is limited to a rubber-like substance.
However this will change. A recent 3ders article reported
that two students from Philadelphia University – Matt Flail
and Tim Ganter – may have an answer through their
FOOTPRINT project which “aims to produce cutting
edge footwear (running shoes) through 3D scanning,
algorithmic models and 3D printing”. Not only did they
want to produce custom running shoes that fit exactly,
produce minimal waste and can act like an orthotic, they
also wanted them to last.
“The biggest insight we found was that a huge issue with
orthotics is trying to correctly fit them into footwear. You
could have an orthotic that fits your foot perfectly and
supports it correctly when laid flat on the ground, but if it
doesn’t fit into the sneaker correctly it can do more harm
than good,” Flail told 3ders.
Their research made them look at all technologies from
shoe parts to prosthetic limbs and more in a bid to
“rethink manufacturing”. By combining certain software
packages it allowed them to manipulate the size, shape
and position of the cellular structure in the materials to
copy the cushioning provided by EVA foams.
“With this technique we can essentially create variable
density midsoles based on specific support needs using
only one material and one basic geometric structure,”
he said.
“Alignment issues can finally be corrected at the source
of the problem without having to produce orthotics that
often don’t match up to standard sizing footwear.”
Once the team got the custom and midsole support
figured out they dealt with the uppers. They teamed up
with Shima Seiki knitting machines to produce a whole
garment process.
“Our uppers were knit in one piece with heat shrink yarn
woven into them. Once knit, the uppers were placed
around the foot last and steamed, which moulded the heat
shrink yarn around the foot for a perfect fit,” Flail said.
They believe this system, although still in need of further
development, is on the way to providing a long lasting shoe.
Member Don Scott who has been making orthotics for
over 30 years said 3D technology was the future and he
was using it.
“In 2010 I was shown the 3D scanning system from
Footpoint which replaced my Footmaxx Gait Analysis
system, but now there are about 30 3D Scanning systems
to choose from. I currently use the Herreen Radial Arm
Scanner which works well for me. It is good to see there
FOOTPRINT design and concept

3. Footprints Magazine 18
RESEARCH & TECHNOLOGY
are young people out there trying to improve ways
footwear and orthotics are produced,” he said.
Board member Stewart Hayes agrees with both points
of view.
“It is definitely the way things are headed, but is still
in its infancy stage with associated high costs. From a
podiatric standpoint, 3D printing has the possibility to
benefit health care practitioners and the public via custom
designed innersoles, orthotics and footwear - which are
just the tip of the iceberg, they are designing body parts
such as knees,” he said.
“Over time, the processes will be refined for all of the
products and then repeated en masse and when this
occurs, the costs will come down thus the general public
will take to it.”
3D technology developer and Pedorthist Jonathan Herreen
said that the next five years will see much change in the
orthoses and footwear industry but warns not to spend too
much on new technology as it will get out of date quickly.
“3D printing is just the start of things to come. Everybody
is jumping on this technology right now…but don’t spend
lots of money on expensive technology as it will be out of
date shortly after you unwrap the box,” he said.
If you have any interesting 3D experiences please
share them by emailing eo@podiatry.asn.au for the next
Footprints.
If you can spare a few hours now and then, the clients will really appreciate your help.
Anyone considering offering their services will be warmly welcomed! We can buddy
you with a fellow podiatrist or you can go with a friend and add your time to CPD hours.
For inclusions and information
please call Alexandra Viles on 0403 056 234
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