The Embrace Insole solution
A dedicated manufacturing system for producing Programmable Foam® orthopedic insoles—an advanced 3D printing technology.
Embrace Insole solution - everything you need in a bundle
The Solution:
- Specifically designed for printing orthopedic insoles in Programmable Foam using soft TPU.
- Eliminates the need for extensive knowledge of printer specifications and materials.
- Reduces waste and post-processing, to save valuable time and effort.
InsoleMaker - Advanced 3D printer
- Optimized for soft TPU, specifically for seating applications.
- Workspace dimensions: 390x235x145 mm.
- Material properties: Certified and approved TPU filament.
- Automatic extraction for 24/7 production.
- Automatic calibration.
- Power efficient – normal operation <150 W.
REALvision Embrace
A streamlined workflow from 3D model to printed product
REALvision Embrace CAM software supports a smooth, three-step workflow to produce personalized 3D-printed orthopedic insole solutions. It starts with preparing the 3D model and ends with a ready-to-print, customized design.
1. Prepare your 3D model
Start by preparing a 3D model in your CAD software that reflects the user’s anatomy and needs. This can be based on a 3D scan, pressure analyse, walk and visual analyse using patient-specific data to define custom comfort and support zones. This design file forms the foundation for targeted customization in the next steps.
2. Define soft and hard zones
With the 3D model ready as stl or obj, import the file into REALvision Embrace CAM to define precisely where soft and hard zones are needed. Apply paintable surface-based modifiers with adjustable brush sizes or embed shape-based modifiers from the built-in library. An intuitive slider helps fine-tune each zone, while our patented technology ensures seamless gradient transitions for optimal comfort and support.
3. Preview and print
Use the built-in visualization tools—like the modifier overlap view—to preview how the modifiers will be applied in the final print. You’ll also get accurate estimates of print time and material usage, helping you plan and manage production efficiently.
Printing material
Programmable Foam® is our patented 3D-printed foam technology that replaces traditional molded foams in custom insole applications. It offers superior comfort, hygiene, and performance, engineered entirely from our specialized CREAtech TPU (Thermoplastic polyurethane) material.
The material and structure of Programmable Foam® bring multiple advantages:
- Non-absorbing and washable: The foam does not retain moisture and can be safely washed in a standard washing machine at up to 60°C (140°F), making it easy to clean and maintain.
- Fire-retardant: Tested and compliant with EN 1021-1, EN 1021-2, and ISO 16840-10 fire safety standards.
- Biocompatible and skin-safe: The material has passed critical biocompatibility assessments: Cytotoxicity testing according to ISO 10993-5:2009 and in vitro sensitization following ISO 10993-10:2021.
- Acute skin irritation in compliance with ISO 10993-23:2021.
These validations confirm the foam’s safety for prolonged skin contact and use in health-related applications. - Free from harmful substances: It is RoHS III compliant and free from Bisphenol A (4,4′-isopropylidenediphenol).
- From a sustainability standpoint, 3D printing with CREAtech PF TPU generates virtually zero waste, and when paired with a TPU recycling scheme, significantly reduces the environmental impact compared to traditional foam manufacturing.
- The clean, dust-free additive manufacturing process makes it possible to produce seats and cushions in standard office or workshop environments—without the need for special ventilation systems.
Onboarding, training, and long-term reliability
Getting started with 3D printing can feel like a big step—but our dedicated customer success team ensures that it’s a smooth one. From the moment your Embrace solution arrives, we’re by your side to help you set up, learn, and grow with the technology.
Step-by-step onboarding
We guide you through the setup of both hardware and software, so you’re ready to begin production from day one. Every stage is designed to be straightforward, with clear instructions and personal support to make the transition easy and efficient.
Training and knowledge sharing
To help you get the most out of your Embrace solution, we provide comprehensive user guides, video tutorials, and tailored training sessions. As new features and improvements are released, we make sure you’re always up to date—so your workflow keeps improving with time.
Ongoing customer support
We’re here whenever you need us. Whether it’s answering questions, troubleshooting an issue, or offering advice, our team works closely with both you and our engineers to support reliable, high-quality production.
Logistics and material management
We take care of order processing for printers, materials, and spare parts—keeping your inventory stocked and your delivery schedule clear. You always know what to expect, and when.
Creative and technical services
From functional print files to label and sticker designs, we support both the technical and visual aspects of your products. We also offer print services where needed—delivering parts with precision and attention to detail.
Built-in maintenance and spare parts
To maintain consistent print quality, our service model includes the proactive shipment of critical spare parts. Each year, we send essential wear-and-tear components to keep your printer running at its best.
If additional parts are needed—due to damage or unexpected wear—they’re always available for quick delivery, helping you avoid unnecessary downtime.
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Produce insoles with this solution
Integrate with your CAD system
Upgrade to mass production without missing the advantages of a simple and sustainable solution.
Integration into your CAD software makes it possible to prepare the print and add the insole to the print management system in one go, using a cloud-based version of the REALvision software engine.
With several printers connected, you can have a central print farm or manage several printers in local store locations, creating a decentralized print farm.
How to get started with 3D printed insoles
We are prepared to assist you in implementing a digitalized workflow and starting production through 3D printing.
- Define your business case.
- Create samples.
- Determine a suitable solution.
- Control and initiate production.
- Scale production.
24/7 production with Automatic Extraction
Increase your production hours effortlessly with this innovative feature.
The automatic extraction option presents a seamless enhancement to the Embrace Insole solution, allowing production to continue beyond regular office hours. With this advancement, the insole is automatically detached and gently guided down a ramp, sliding into a designated box. A built-in camera diligently assesses the success of the extraction.