3D printed fluid-filled biocompatible composite insoles for enhanced foot comfort
Custom-graded, fluid-filled 3D printed lattice insoles designed to reduce foot stress and improve comfort during daily activities. Developed using plantar pressure data and advanced additive manufacturing, these biocompatible composite insoles offer continuous self-adjustment tailored to individual users.
Overview
This solution introduces custom-graded insoles manufactured from solid-liquid biocompatible composites using 3D printing technology. Designed to alleviate foot pain and enhance cushioning, the insoles feature fluid-filled lattice structures that provide continuous self-adjustment during use. By integrating a daily plantar pressure optimisation algorithm with computational modeling and additive manufacturing, the technology delivers personalized support that targets specific pressure points, minimizing maximum stress on the foot and improving overall comfort and mobility for users across a range of daily activities.
Technical specifications
Key features:
- Fluid-filled lattice architecture: 3D printed unit cells with strategically manipulated shape and properties to enable targeted stiffness and softness adjustments across specific insole regions
- Biocompatible solid-liquid composite: Materials selected for safe, prolonged contact with the foot
- Plantar pressure-driven design: Wireless pressure sensor data captured during walking and running informs the graded configuration of each insole
- Custom-graded optimization: Algorithm-driven design that tailors unit cell settings to minimize maximum foot stress for individual users
- Additive manufacturing process: Produced using 3D printing capabilities at the CAMMD lab, University of Auckland
Technology readiness level
A functional prototype has been developed and is currently undergoing clinical trials. Ethics approval has been obtained, and a study involving 30 participants actively using athletic footwear has been initiated to measure plantar pressure distribution during day-to-day activities. The same participant group is being engaged in comprehensive clinical trials to assess comfort, efficacy, and impact on foot stress reduction and mobility. Statistical analysis of the collected data is underway to validate the correlation between designed insole properties and observed reductions in maximum foot stress. The technology is at a prototype-to-validation stage, with ongoing clinical evidence gathering to support further development.
About University of Auckland
The University of Auckland is a comprehensive public research university—New Zealand’s largest—serving a broad research portfolio and a large, diverse student body. Research is anchored across adjacent city and Newmarket sites with shared core facilities, pilot lines, and test halls; the health campus sits beside major Auckland hospitals, enabling clinical translation. UniServices, the university’s commercialization company, provides a single front door for contracting, IP management, and venture formation, with experienced teams to deliver multi‑party programs. Research is supported by competitive funding from New Zealand’s major agencies and international sponsors, including programs administered by MBIE, the Health Research Council, and the Marsden Fund. Dedicated tech transfer, incubator links, and prototyping resources help partners move from discovery to pilot and scale‑up.
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