Midsole and insole designs are generated using Simpleware lattice structures from original CAD files and 'boolean' a variety of solid surfaces to the lattice structure. Lattices are based on the original solid STL file, and are straightforward to generate for virtually testing out different designs based on unique foot and gait characteristics. For example, areas of the sole that need to be more or less flexible, such as the heel and arch areas, can be easily thickened or reducing using Simpleware's morphological 3D editing tools.
The resulting designs are used to manufacture parts using a variety of thermoplastic polyurethane powders for SLS as well as elastomeric resins for DLP/SLA printing systems. This approach allows for an infinitely variable range of manufacturing options and sizing without having to rely on a mold, reducing waste in the form of excess scrap material that usually comes from traditional molding process.