DIY custom insoles don't have to be complicated. With a parametric insole design platform like Ergono3D, you can generate a print-ready STL in minutes — no specialist training, no expensive equipment.
The biggest misconception about "custom insoles" is that they must be hard to make — hand-carved by a specialist, formed from plaster casts, pressed in a clinic, and sent to a lab. To be fair, that's still the reality of the traditional process in many places.
A typical pair of traditional custom insoles goes through:
- Visit a clinic for a foot assessment
- Capture foot shape using plaster, foam box, or a professional scanner
- Send data to a lab
- Technician creates the mold by CNC or by hand, adds top cover and finishing
- Wait several days — or one to two weeks — to receive the final product
This process isn't just slow. It relies heavily on individual technician experience — two different technicians can produce insoles that feel different, and consistency is hard to guarantee. Equipment is expensive, labour is expensive, the workflow is complex.
Today, things are genuinely different. With a home 3D printer, that long traditional chain compresses into three steps:
With Ergono3D, your personal insoles can improve over time — just like software updates — until they feel truly right.
What you'll need. (~30 seconds to check)
- A home FDM 3D printer capable of printing TPU
- TPU filament — 95A (recommended for most use cases)
- Slicer software — Bambu Studio / OrcaSlicer / Cura (any one)
- An Ergono3D-generated STL file
Generate the STL in Ergono3D.
Sign up or log in at ergono3d.com. You can register directly or use your Google account.
Every new user gets 5 free Preview credits. Click Create New to start.
Enter a name for the file. Under User Type, choose Man, Woman, or Youth. Select your shoe size, then click Next.
Choose the intended use case for your insoles, plus the arch type and wear pattern that match your feet. Then click Next.
Select your Discomfort Areas (multi-select), use scenarios, Priority, and Shoe Type. Then click Next.
Optionally share a bit more about your needs to help the system understand your requirements better. Then proceed to the next step.
The system has generated a 100% personalised insole STL file based on your inputs. Download it and move to the next step.
Configure your slicer settings.
After importing the STL into your slicer, use this beginner-friendly, reliable baseline profile for TPU 95A:
| Setting | Recommended value |
|---|---|
| nozzle_temp | 235°C (range: 220–250°C) |
| bed_temp | 55°C (range: 45–60°C) |
| max_volumetric_speed | 3.2 mm³/s |
| print_speed | 25–50 mm/s |
| infill_pattern | Gyroid |
| infill_density | 20% |
| retraction | 0 mm (OFF) |
| cooling_fan | 100% max |
For TPU 85A and 90A settings, see the full print settings table on the Pricing page →
Click print.
Two things to watch during the print:
- Make sure the first layer sticks to the build plate. If it doesn't, stop and restart — a failed first layer means a failed print.
- If you see severe warping mid-print, stop immediately. Continuing will almost certainly ruin the part.
In most cases, a pair of insoles will finish after a few hours depending on printer speed and infill density.
Finishing after the print.
- Remove the insoles and trim off the brim (if any) with scissors.
- Use small scissors or sandpaper to gently round the edges — especially around the heel where sharp edges can rub.
- Add a top cover layer — EVA foam, Poron, or fabric — for comfort, sweat management, and friction control.
Wear test feedback. Optional, but highly recommended.
If you want the next version to feel better, three notes are enough:
- Where it feels too high or rubs: forefoot / inner arch / outer arch / heel edge
- Support feel: too stiff / too soft / just right
- Where fatigue or hotspots appear first: heel soreness / arch fatigue / tight calves / knee discomfort / friction points inside the shoe
Quick fixes. 90% of failures happen here.
- WARPING · LIFTING OFF BED Increase the brim. Raise bed temp slightly. Use a glue stick or painter's tape on the build plate.
- STRINGING TPU is moisture-sensitive. Temperature may be too high. Retraction may not be ideal. Dry the filament first — this solves the majority of stringing cases.
- BUBBLES · HOLES ON SURFACE Filament is wet. Dry it first (65°C in a food dehydrator or oven for 4–6 hours).
- WEAK LAYER BONDING Printing too fast, nozzle temp too low, or cooling fan too high. Slow down, raise temp slightly, reduce fan.
- EDGES RUBBING FEET Round the edges manually. For the next version, choose a geometry with softer edge transitions.
- TOO STIFF Lower infill density. Reduce wall count by one. Choose a softer structure in the next generation.
- TOO SOFT Increase infill density. Add more walls. Choose a more supportive version in the next generation.
Try Ergono3D to generate your own custom insole design with parametric control and STL export. Free preview — 5 credits, no card required.