Partnering with a materials science company, I led a four-week research sprint to stop 3D-printed insoles from creeping under load. Orthopedic shoemakers liked the customisation of FDM TPU shells, but the lifetime performance was unacceptable. We needed a composite structure that stayed flexible, carried weight, and still allowed post-production tuning.
Rapid Material Experimentation
Our hypothesis was to combine a printed 95A TPU shell with a secondary filler that carried compression loads. I structured the experimentation backlog so the team could test synthetic rubber, silicone, and PU foam infills in parallel. Each build went through standardised flex and compression tests, making it easy to compare candidates week to week.
User-Centred Requirements
We interviewed traditional shoemakers to understand the finishing touches they need. Their feedback was clear: the insole must feel hand-crafted, be modifiable after delivery, and support iterative fittings. Those insights guided our geometry choices and the way we encapsulated the filler, ensuring technicians could trim or heat-adjust the insole without compromising the core structure.
Business Model & Supply Chain
I designed a SaaS platform concept that gives shoemakers subscription access to design tools and print-ready profiles. The roadmap included vertical integration into proprietary filler materials—turning ongoing replenishment into a predictable revenue stream while giving craftspeople consistent performance.
Lessons & Next Steps
- Early composites underperformed pure TPU, which validated our approach and highlighted the need for a higher compressive strength filler.
- Documented a test protocol and data room so the partner company can continue R&D after our sprint.
- Strengthened skills across material science, 3D printing process control, qualitative research, and go-to-market planning.