About

Custom insoles, rebuilt as software.

Ergono3D is a browser-based design tool that turns guided foot inputs into custom 3D-printable insole and orthotic STL files — parametric arch, heel cup, posting and skive, with no CAD and no 3D scanner. Built in Australia for clinicians, labs and makers.

What we do

From foot inputs to a print-ready STL.

Most custom orthotics are still designed the old way: a clinical visit, a plaster cast or scan, a lab queue, and a finished device weeks later. Ergono3D moves the design step into the browser. You describe the foot and its use case through a guided survey, the software generates parametric insole geometry, and you fine-tune it with the same controls an orthotic designer would use — then export a print-ready STL for any FDM printer that handles flexible TPU.

  • 01 · Smart inputA short activity-based survey captures foot needs, footwear, and use case.
  • 02 · ParametersAccept smart defaults or tune arch height, heel cup, posting, skives, flange and forefoot geometry.
  • 03 · Scale & fitThe model is automatically scaled and validated for printability.
  • 04 · PrintDownload the STL and print in TPU on Bambu Lab, Prusa, Creality and similar printers.
Why we built it

Good insoles shouldn't require a lab queue.

Traditional clinic-made custom orthotics commonly cost $300–$600 per pair and take one to two weeks from cast to delivery — which puts them out of reach for many people who could benefit, and makes iteration slow for the clinics that prescribe them. Meanwhile, desktop 3D printers and flexible TPU filament have become good enough to produce durable, comfortable insoles on a desk.

What was missing was the design layer: a way to go from a real foot to printable orthotic geometry without CAD expertise, scanner hardware, or lab infrastructure. That is the layer Ergono3D builds. The same parametric workflow serves a maker printing one pair at home and a clinic processing patient cases in-house — see how it compares to outsourcing in our clinic cost & ROI guide.

How we approach design

Parametric geometry, grounded in biomechanics.

Every Ergono3D design is generated from named orthotic parameters — arch height and profile, heel cup depth, rearfoot and forefoot posting, medial and lateral skives, flange coverage — rather than free-form sculpting. That keeps designs repeatable, explainable, and easy to iterate: change a parameter, and the geometry updates. Our parameter guide documents what each control does and when to use it.

Where we draw the line: Ergono3D is design software, not a medical device — it does not diagnose conditions or replace clinical judgement. Health-related articles on our blog reference independent clinical sources (such as Cleveland Clinic and peer-reviewed research), and we keep product claims to what the software actually does: generate custom, printable insole geometry.
Who we serve

One workflow, three kinds of users.

Makers & athletes

Design and print your own insoles at home — from everyday comfort to sport-specific setups. Start with the maker guide.

Clinicians & podiatrists

Bring orthotic design in-house: represent each patient's needs in the guided input, apply clinical corrections, and print same-week. See the clinic workflow.

Labs & studios

Replace plaster casting with a repeatable parametric pipeline and high-volume credit packs built for production. See plans.

The company

Built in Australia, printed worldwide.

Ergono3D is built by a small Australian team working across software engineering, 3D printing, and footwear geometry. Our 3D-printed midsole and insole work has been covered by Fabbaloo.

See it yourself

Preview a custom insole in minutes.

The free preview includes the guided survey and an interactive 3D model — no credit card, no CAD, no scanner.

Start free → Email the team