1
3D Scan
In minutes, the feet are scanned with sub-millimetre accuracy, at home using the Solemate iOS App or during consultation with one of our Retail Partners where any specific needs can be discussed.
2
Analysis
Using specialist software developed together with podiatry experts, a precise CAD model of your insoles is created including any corrections necessary to improve alignment, comfort and performance.
3
3D Print
Insoles are printed at our state-of-the-art 3D printing facility, undergoing rigorous quality control and testing. Insoles are shipped either for in-store collection, or direct delivery.
Product Testing is a serious business.
How does 3D Printing work?
Turning your orders into reality
At our UK-based 3D print farm (yes, it's really called a print farm!) we process your scan data into insole designs ready for production. In-house manufacturing enables us the shortest lead times in the industry and tighter quality control. Starting from a single machine, we now operate a large network of interconnected 3D printers, modified specifically to face the challenges of insole production. They run 24/7, largely unattended.
Creating a 3D Printed Insole
Slicing
Using the biodata from the 3D scan we are able to create a CAD model for onscreen analysis. Once a digital insole file is created, it needs to be 'sliced'. This process converts the geometry and properties into a long line of code that the printers are capable of interpreting. These instructions define the exact movements, speeds, temperature and extrusion of material through printing. This can be as many as 250,000 unique lines of code for an individual insole!
FDM Printing
Fused Deposition Modelling is our core printing process used at Solemate. Filament (a long spaghettilike strand of flexible plastic wound onto a spool) is melted and pushed through a narrow nozzle. The settings defined during slicing determine the path of the nozzle as it traces out a cross section of the insole. This creates a single almost 2D layer which cools and solidifies. The printer then deposits another layer on top of the first, and so on, repeating until an insole is formed.
Post-Processing
Taking up to 6 hours to print each insole, upon completion the print is removed from the bed and inspected. Any loose strands of filament are tidied up with a light sanding, before packaging up for dispatch. Simple (sort of!).
Understanding Customer Needs
We've worked hard to create a platform that digitises the process of building custom insoles without loosing the human touch. Our intuitive interface allows for flexibility when inputting information and our hand picked Retail Partners take the time to understand your requirements.
Ongoing Updates
3D Printing doesn't face the same limitations as conventional manufacturing. We can implement improvements instantly and are always looking at ways to develop our products to ensure customers receive our most innovative offering. Please do reach out if you think there's something we could do better!
Leveraging Technology
We live in amazing times with powerful tools at our fingertips. Everything we do at Solemate seeks to maximise this to elevate the customer experience, delivering a world-class product that has never been more convenient. What excites us most is where we're going next!
