Technology & science

Mapped to the millimetre.
Printed to the patient.

Every Shapecrunch device begins as a precise digital model of one person's foot — then becomes a 3D-printed orthosis engineered to their biomechanics.

Foot reconstructed as a 3D mesh on a custom orthotic
Step 1 — capture

2,000+ points, one true model.

From in-app photographs — and an optional pressure-mat scan and gait video — we reconstruct the foot as a dense 3D mesh. No two feet are alike, and often one foot differs from the other; the model captures both.

Arch profile mapped along the foot
Step 2 — design

The arch, drawn to your prescription.

We map the arch profile and pressure points, then position support exactly where the foot needs it — accommodating deformity and steering gait and posture back towards neutral.

3D printing a custom orthotic
Step 3 — print

Two layers. Variable density. One shell.

  • BASE 3D-printed TPU — rubber-like, durable, with a spring-like return underfoot.
  • TOP Premium EVA / Poron for natural shock absorption.
  • TUNE Density varies along the device: flexible forefoot, semi-rigid arch, stiff heel cup to control valgus and varus.
The corrections

Engineered elements, prescribed per patient.

Arch support
Arch support

Redistributes pressure; controls over- and under-pronation.

Medial wedging
Medial / lateral wedging

Shifts angulation; eases valgus knee load and instability.

Deep heel cup
Deep heel cup

Foot and ankle stability; neutralises corrective forces.

Metatarsal pad and offloading
Met pad & offloading

Supports the metatarsals; offloads ulcers, corns and calluses.

Before and after overpronation correction
Why it matters

The foot is the foundation of the body.

Feet, knees, hips, back and neck are linked. Uncorrected flat foot and overpronation are common drivers of back pain and knee osteoarthritis. Realign the base, and the chain above it follows — the principle behind our work on plantar fasciitis, heel pain, supination, limb-length discrepancy and the diabetic foot.

See conditions we address →

Podiatrist-grade orthoses, on demand.

Order from the app, or book a demo to see the full workflow.