Case Study: Phits™ Insoles achieves 400% production growth and scalable, sustainable 3D‑printed orthotics with Materialise

The World’s First Dynamic 3D-Printed Orthotics

Phits™ Insoles, the world’s first dynamic 3D‑printed orthotics built from gait analysis, faced the challenge of turning dynamic foot data into personalized, high‑quality insoles at scale. Materialise partnered with Phits™ Insoles to replace static imprints with a streamlined additive manufacturing process, addressing the complexity of certified production lines while preserving design fidelity, consistency, and sustainability.

Materialise implemented an end‑to‑end workflow using Materialise 3‑matic, workflow automation, a cloud portal and the Streamics production system to automate design, manage machine scheduling, labeling and track‑and‑trace, and print orthotics from 100% recycled powder with 0.1 mm accuracy. Process optimizations — changing the laser scanning pattern (cutting laser passes from ~200 to 1), improving nesting and orientation, and tweaking lattice beam sizes — reduced unit costs and lead times, improved accuracy and productivity, and helped Materialise grow Phits™ Insoles production by more than 400% worldwide in four years.

Phits™ Insoles