Stepping into the Future: Transforming Footwear Comfort and Performance with Personalised 3D-Printed Insoles and Midsoles
Advanced 3D printing is revolutionising orthotic therapy by enabling footwear solutions precisely tailored to an individual’s anatomy and biomechanics. Unlike traditional prefabricated or labour-intensive custom devices, these technologies use foot scans, pressure mapping, and gait analysis to produce insoles and midsoles that match unique foot geometry and pressure distribution. This precision allows for improved comfort, targeted offloading, and enhanced performance.
The presentation will review clinical applications across diabetic foot care, plantar fasciitis, arthritis management, and sports performance. Evidence shows that personalised 3D-printed insoles can reduce high-risk pressure areas, modify gait biomechanics, and even enhance energy return and impact absorption in athletes. Case studies will illustrate both therapeutic benefits and performance gains, highlighting how lattice structures and tuned midsole designs deliver measurable outcomes.
Participants will also gain an overview of the main 3D printing technologies used in footwear—FDM, SLS/MJF, DLP, and PolyJet—along with insights into the personalised design process. Future developments, including new materials, AI-driven design, and improved accessibility, will be discussed, outlining how these innovations are set to expand the clinical and performance potential of personalised orthotics in routine practice.
Dr Sayed Ahmed
Dr Sayed Ahmed
Clinical Researcher and Pedorthist ||
Foot Balance Technology
Dr Sayed Ahmed is a foot healthcare professional, entrepreneur, researcher and accomplished leader in Pedorthics and medical device innovation. He became the first PhD in Pedorthics in Australia. He completed his PhD from Southern Cross University, focusing on diabetic foot care and personalised footwear prescriptions.
Dr. Ahmed began his career with a B.Sc. Engineering & Tech. in Footwear from the University of Dhaka, and later earned an MBA in Management Information Systems. His professional journey includes significant roles as founder and CEO of Foot Balance Technology and OrthoGenix, where he developed innovative solutions for foot health challenges, particularly for individuals with diabetes. His innovation focuses on enhancing the patient experience through the use of 3D and digital technologies, including scanning, CAD design, additive manufacturing, and AI integration for decision-making and process improvement in clinical practice.
Dr. Ahmed has secured and managed notable grants, including the "National Industry PhD Program," which focuses on AI-powered clinical decision support systems (CDSS) and has collaborated extensively with Australian universities. His research, widely published, encompasses topics such as footwear design for diabetic foot ulcers and AI-driven medical device prescriptions. Dr. Ahmed is dedicated to advancing foot health through interdisciplinary collaboration, mentorship, and innovative research
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