Revolutionising Insole Production with SLS 3D Printing

Selective laser sintering (SLS) 3D printing is rapidly transforming the insole production industry. This cutting-edge technology offers numerous advantages over traditional manufacturing methods, enabling the creation of highly customised and functional hard shell insoles.

The SLS Process

The SLS process begins with a digital 3D model of the insole, typically created from a scan of the wearer's foot. This model is then sliced into thin layers, which serve as a blueprint for the 3D printer.

Slicing of insoles into the build chamber

 

Inside the printer, a bed of fine polypropylene powder is meticulously spread by a roller mechanism. A high-powered laser selectively fuses the powder particles together, following the digital design layer by layer.

A finished print inside our Formlabs Fuse 1. The recoater can be seen on the left side of the print.

Depowdering and Cleaning

Once the printing process is complete, the entire build chamber is removed from the printer and transferred to a separate sifting station. The 'Cake' is removed from the buildchamber here, excess powder is carefully sifted and reclaimed for future use, minimising waste.

The printed 'Cake' is removed from the build chamber

 

The insoles are covered in unsintered powder that can be recycled. 

 

The depowdered insoles are then meticulously cleaned in a separate cleaning station to remove any remaining powder particles.

SLS printed insoles in polypropylene being cleaned and de-powedered

This cleaning and sandblasting process ensures a smooth and comfortable final product.

3d Printed Insoles awaiting sandblasting

 

 

A finished sandblasted insole

What are the benifits of SLS printing insoles?

• Design Flexibility: SLS technology enables the incorporation of complex design features into insoles, such as lattice structures for variable cushioning or integrated arch support.
• Durability: Polypropylene is known for its strength and durability, making SLS insoles ideal for everyday wear and high-impact activities.
• Reduced Waste: Unlike traditional manufacturing methods that generate significant waste material, SLS printing is a more sustainable process, as excess powder can be reused in subsequent prints.

Want to know more?

Get in touch by email or phone and one of our product specialists will let you know how we can help your clinic and patients with 3d printing. 

 

How do I order?

We have an order chart and guide to ordering.