From the First Digital Insole Model to an Automated Design System

pedcad has been developing digital design solutions for orthopedic devices for over three decades.

As early as the early 1990s, pedcad introduced the first "Insole Designer" for the digital design of custom shoe insoles. Then as now, the technological foundation was "Pictures by PC" from SCHOTT SYSTEME.

The goal was clearly defined from the start: the design of custom insoles was to be carried out digitally without limiting the craftsmanship involved in orthopedic shoemaking.

While many CAD systems were developed for technical engineers, pedcad created a solution tailored to the workflows of orthopedic shoemakers.

Digitally Replicating Manual Craftsmanship Steps

Designing custom orthopedic devices follows established principles of craftsmanship. Arch supports are built up, pressure peaks are relieved, footbeds are modelled, and corrections are incorporated.

pedcad analyzed these steps and translated them into digital tools. 

The result was a CAD system that speaks the language of the craft and aligns with actual orthopedic treatment workflows. 

Over the years, additional areas of application were added. 

In addition to insole design, solutions were developed for:

• Digital last construction for orthotic insoles
• Digital last manufacturing
• Prosthetic sockets
• Shell soles
• Orthopedic shoe components
• Digital manufacturing processes in orthopedics and orthopedic shoemaking

Continuous Development Based on a Proven Foundation

The "Pictures by PC" technology remains the foundation of this development to this day.

Building on this, pedcad has been developing its own user interfaces, tools, and industry-specific functions for over 30 years.

The result is software that harnesses the power of a professional CAD system while being designed for users without formal CAD training.

From Milling to 3D Printing

In the early years, digitally designed insoles were primarily manufactured using CNC milling technology.

As additive manufacturing processes evolved, the digital workflows were expanded accordingly. Today, insole models can be exported as 3MF files and automatically transferred to slicing systems.

This creates a digital workflow that spans everything from analysis and design to automated 3D printing production.

Automated Design Based on Measurement Data

A key step in development was translating clinical fitting expertise into algorithms.

Drawing on experience from millions of fitting cases, pedcad developed a design algorithm capable of automatically generating custom insoles from measurement data.

Depending on their preferred workflow, users can now:

• Design manually
• Semi-automatically
• Generate insoles fully automatically

The process relies on inputs such as 3D scans, pressure measurements, or practice-specific fitting guidelines.

Digital Orthotics Technology in Over 60 Countries

Today, pedcad’s technology is used in more than 60 countries.

Despite numerous enhancements, the original objective remains unchanged:

To make traditional craftsmanship expertise digitally accessible without compromising the individuality of the fitting.

Design software - pedcad foot technology