How to Customize Footwear Using a 3D Laser Foot Scanner

‍Custom shoe manufacturing with a 3D laser foot scanner follows this main workflow: capturing 3D foot data → computer workstation (reverse modeling + last CAD) → 3D printer (last printing) → cutting, stitching and molding production line.

1.Capture 3D foot data via the 3D laser foot scanner.

  This step is critical. Inaccurate measurement data will result in shoes that rub the feet and other fitting issues.

  During scanning, the user stands barefoot within the scanning area of the foot scanner. Throughout measurement, maintain body balance with even weight distribution on both feet, keep the body steady, look straight ahead and stay relaxed. The heels should align closely with the positioning reference line, feet placed squarely; avoid tiptoeing or swaying.

  Scanning is conducted under supervision of professional technicians. The whole process takes only dozens of seconds. Upon completion, a visual measurement report and 3D data in STL format are generated simultaneously.

2.Reverse modeling and shoe last CAD design.

  After acquiring STL data, import the files into professional software for noise reduction and mesh repair. Commonly used software includes Geomagic, Rhino, dedicated shoe last CAD software, etc.

  Design fitting allowances, toe box space, heel contour tightening and instep tightness according to the shoe style selected by the customer.  

  Modeling is carried out based on imported data to convert the physical digital foot model into a digital shoe last.

3.Shoe last fabrication.

  Export the finalized shoe last data and conduct data processing. The processed data is imported into a 3D printer or dedicated CNC shoe last equipment for last production.

4.Upper pattern development, material cutting and stitching.

  Based on the customized digital last, develop upper patterns in shoe CAD software, supporting personalized design for the toe cap, quarter, heel counter and tongue.

  According to design data, perform CNC cutting of leather/fabric, then cut and stitch the upper, lining, foam padding and other components.

  The stitched upper is fitted onto the exclusive personalized shoe last. Operators or machines stretch the upper and attach the insole, followed by thermal shaping to make the leather permanently conform to the individual foot contour. Demolding takes place after cooling and curing.

  Finally, conduct polishing, painting, stitching and fitting inspection.