3D printed medical insole in green foaming TPU material, stacked on top of a large spool
INSOLUTION x BEDROCK 3D

Foaming TPU x GO1: The Game-Changer in 3D Printed Medical Insoles

Rethinking Orthotics: From Craftsmanship to Scalable Precision

A brilliant idea from Insolution: 3D-printing medical insoles to save time, create better insoles, more quality consistency, reduce manual labor, and take a huge step toward a more sustainable future.

But like most good ideas, reality hit hard. The printer didn’t perform, the material didn’t behave, and the connection between all the aspects was missing.

The challenge?
A traditional craft facing modern-day pressure, less specialists entering the field, a shortage production personal and a growing demand for medical insoles, and a material and technology not yet ready to deliver on its promise.

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Years Collaboration & Growth

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Printed Medical Insoles

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KG's Foaming TPU

From Challenge to Collaboration

a pair of printed medical insoles in green Foaming TPU filament material

Filament Development

Custom Made Foaming TPU Filament

We partnered up. Due to our connections, we where able to bring Felix Printers to the table and together with our BEDROCK 3D R&D team we rolled up our sleeves.

The task:
Develop a custom Foaming TPU Filament that combines strength with optimal flexibility, is fully safe for direct skin contact (medical grade), and performs consistently and reliably with the GO1 3D printer, even at scale. 

 

It wasn’t a straight road. Dozens of tests, reprints, and adjustments later, we found ourselves back at the drawing board more than once. Where other material developers had already given up, we kept going. We were determined to make this product a reality and truly help Insolution move forward. The material had to be flexible, durable, and suitable for direct contact with people, no small feat. But we got there.

Green orthotics 3D printer close-up

One-Stop-Solution

Green Orthotics | The GO1 3D Printer

Our Solution:

What we created together is a custom-made Foaming TPU Filament that works seamlessly with the GO1 printer.

  • Within just 90 minutes, a pair of medical insoles rolls out, ready to use.
  • An insole that is better in solving foot related problems and is more hygenic
  • A hardness that can be defined throughout the whole insole.

Compared to traditionally handcrafted medical insoles, 3D-printed orthotics offer far greater precision, resulting in a medical insole with a perfectly tailored fit. Where traditional insoles depend on the experience and steady hand of their maker, 3D printing guarantees that every pair is nearly identical in shape and quality.

With our BEDROCK 3D x Insolution GO1 Insole TPU and a few smart software adjustments, we can now print layers as thin as 1 mm. This makes a real difference, especially in the forefoot area.

Recently, when one of Insolution’s end customers shared that she could finally live pain-free thanks to the improved fitting, pressure and cushioning of her 3D-printed insoles compared to her previous traditional ones, we knew for sure: our GO1 solution truly makes a difference for patients in the world of medical orthotics.

An independent podiatrist reported a clear upgrade: beyond the obvious reduction in waste, the insoles offer stronger heel support, a more stable fit, and consistent quality with every 3D-printed pair.

Read the full article here

Partnership Essentials

The secret lies in our partnership resulting in a perfect balance of filament material, hardware and software.

  • Experience in 3D Printing & Filaments test

  • Open and Honest Communication

  • Committed to find a Real Lasting Solution

  • Full Solution Thinking

We were looking for a strategic partner to solve the challenges in our market. A company that is willing to work very closely with us to get to the perfect result. BEDROCK 3D proved to be just that. A team with capable people who had the energy and passion to go only for the very best.

Logo from Insolution in blue and red colors

Rob Hendriks

CEO Insolution | Green Orthotics
Close-up of a Green Orthotics 3D printer producing the midsection of a medical insole, highlighting the clean and sharp inside print quality
Built for Professionals

Complete Concept

Today, Insolution’s Green Orthotics concept gives podiatrists and specialists everything they need: reliability and consistency due to the GO1 printer, BEDROCK 3D’s Foaming TPU, software, and service, all in one plug-and-play system.

For us, it’s the perfect partnership. A steady base of material demand, powered by collaboration and innovation, exactly what BEDROCK 3D stands for.

Let's talk!

We believe this all-in-one plug-and-play system has the potential to go far beyond custom-made insoles, into wear and protective gear, sports applications, and more.

We’re always open to new ideas and can’t wait to hear yours!

Send a message
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