From FFF to SLS: Raise3D RMS220 Helps LutraCAD Scale Custom Insole Production
LutraCAD is a software solutions provider based in the Netherlands, serving primarily the orthotics and prosthetics market. Its specialist software supports the design and production of custom insoles, shoe lasts, midsoles and related orthotic products, helping customers establish digital workflows tailored to individual needs.Since 2016, LutraCAD has explored how to incorporate 3D printing into its customers' production processes, evaluating additive manufacturing technologies including fused filament fabrication (FFF), stereolithography (SLA) and selective laser sintering (SLS).
Initially, FFF was a key focus because of its relatively low barrier to entry and straightforward deployment. As customers' requirements for rigid-shell insole quality and production efficiency increased, LutraCAD needed to address three challenges: achieving better surface quality, producing thinner insole structures and reducing manual intervention in batch production.
Rapid development and the challenges of scaling production
LutraCAD previously relied mainly on FFF printing and milling to produce insoles. Both processes met needs at different stages, but each presented limitations when scaling custom insole production.
Product and efficiency limitations of FFF
FFF supported early development in LutraCAD's applications. As production requirements increased, however, its limitations became more apparent:
[*]Insole surface quality did not fully meet evolving requirements.
[*]The achievable insole thickness was constrained.
[*]Further improvements in batch production efficiency were difficult.
[*]Operators still needed to check equipment periodically during printing.
Previously, operators using FFF had to check the equipment every few hours.
Milling requires frequent manual intervention
Milling requires operators to inspect equipment frequently, remove excess material, carry out multiple post-processing steps and prepare insoles for delivery. In LutraCAD's previous milling workflow, operators intervened approximately every 20 minutes.
Milling generates substantial material waste
Approximately 80%–90% of the original material block became waste during machining in the previous milling process.
SLS improves insole production efficiency
After testing different additive manufacturing technologies, LutraCAD identified three main benefits of SLS:
Improved surface quality and thin-wall design
Compared with its previous FFF workflow, SLS delivers surface quality better suited to LutraCAD's requirements and supports thinner insole designs.
Insole thickness affects both overall dimensions and the flexibility and support characteristics of different regions. Combining SLS with Raise3D PA11 allows LutraCAD to adjust the thickness of different areas during the design stage.
Batch production within a single powder bed
SLS does not require separate support structures for each part, allowing multiple insoles to be arranged within the same build volume.
With the Raise3D RMS220 SLS printer, LutraCAD can produce 20–25 pairs of insoles per build. Print jobs can run overnight, with the batch completed the following day before depowdering and the necessary finishing steps for delivery.
Actual output depends on factors such as insole dimensions, part arrangement and printing parameters.
A different approach to material use
Milling forms parts by removing material, whereas SLS builds them layer by layer from powder. Unsintered powder from the build can be used in subsequent production in accordance with the relevant process requirements.
Building an SLS workflow for custom insoles with the RMS220
Before introducing SLS, LutraCAD had used Raise3D FFF printers for several years. Its experience with the equipment and collaboration with the Raise3D team provided a foundation for evaluating the RMS220.
When selecting an SLS system, LutraCAD focused on:
[*]Confidence in the Raise3D team and equipment reliability.
[*]Whether the build volume could accommodate batches of custom insoles.
[*]Whether printing speed could support day-to-day operations.
[*]Whether the software, materials and equipment could form a complete workflow.
[*]Whether the solution provider could offer ongoing support.
For LutraCAD, the RMS220 is more than a standalone SLS machine: it is a platform for expanding custom insole production capacity.
LutraCAD's RMS220 workflow is organized around batch builds and consists of five main steps:
[*]Design insoles for different requirements and import the models into ideaMaker.
[*]Arrange multiple different designs within a single build job.
[*]Adjust build packing density and printing parameters in ideaMaker.
[*]Complete batch printing overnight.
[*]Depowder the parts and carry out the necessary finishing steps before delivery.
Reducing manual intervention and simplifying post-processing
Moving from milling to SLS changes the production workflow in several ways.
Less intervention while the equipment is running
The RMS220 supports overnight batch builds, reducing the need for frequent operator intervention while the equipment is running.
LutraCAD can:
[*]Produce batches overnight.
[*]Reduce manual equipment checks during operation.
[*]Simplify the post-printing workflow.
[*]Plan daily output more clearly.
Simpler post-processing
After printing, insoles produced with the RMS220 mainly require depowdering and the finishing steps necessary for delivery. Compared with the previous milling process, the workflow reduces extensive material removal and handling operations.
Improved material use
SLS builds parts layer by layer from powder rather than removing large amounts of material. Some unsintered powder can be reused in subsequent production according to the relevant process requirements.
PA11 balances flexibility, strength and structural design
Based on LutraCAD's application feedback, the main characteristics of Raise3D PA11 include:
[*]A balance of flexibility and rigidity suited to insole design.
[*]High elongation at break.
[*]Support for thinner insole structures.
[*]The ability to adjust local flexibility through changes in thickness.
Insoles with different geometries and local thicknesses can be included in the same SLS build, combining individualized designs with batch production.
ideaMaker connects FFF and SLS build preparation
LutraCAD uses ideaMaker to manage preparation for both FFF and SLS production. In its RMS220 workflow, ideaMaker is used to:
[*]Import custom insole models.
[*]Arrange multiple insoles within a build.
[*]Adjust build packing density.
[*]Set and manage printing parameters.
[*]Prepare RMS220 print jobs.
Adding SLS within the same software environment helps reduce additional software switching and learning requirements.
From individual parts to planned batch production
Before full implementation, LutraCAD trialed the RMS220 for several weeks as an early user. According to LutraCAD's feedback, the system was relatively straightforward to operate, supported routine use and maintained consistent print quality during the trial.
The more significant change extends beyond any individual pair of insoles to the organization of production:
[*]Multiple pairs with different designs can be combined in one build.
[*]Overnight printing reduces equipment supervision during working hours.
[*]Producing 20–25 pairs per build provides a clearer basis for daily output planning.
[*]Moving from milling to layer-by-layer powder processing changes material use.
[*]FFF and SLS production preparation can be managed within the same software environment.
Expanding material options and insole applications
LutraCAD views the RMS220 SLS printer as a platform for long-term production development. Its areas of future interest include:
[*]Access to a wider range of materials.
[*]Greater automation of powder mixing.
[*]Intelligent features to help adjust printing parameters.
[*]Expanded custom insole production.
[*]Further orthotic and functional product applications.
The RMS220 has helped LutraCAD move custom insole manufacturing from technology testing toward a production workflow built around batch builds, overnight operation and digital part arrangement.
AI-translated from the Chinese article by 小软熊 (Xiaoruanxiong), published on October 12, 2026. Original text and images: Nanjixiong.
Read the original Chinese article
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