Fast Track Custom Footwear for Child

Dinsmore NewsPress Release

Irvine 3D Printing Company Dinsmore Inc. Helps Fast Track Custom Footwear for Child in Need

IRVINE, California, December 10, 2019 — Dinsmore Inc., Orange County 3D Printing and Additive Manufacturing services provider with over 25 years industry experience, delivers custom 3D printed orthotics for Imre Patterson, a young boy who was born with a femoral discrepancy (causing one leg to be shorter than the other). Using breakthroughs in both 3D printing technology and materials, the team at Dinsmore Inc. designed an alternative to his traditional manufactured foam boot using Carbon’s Digital Light Synthesis™ (DLS) technology to 3D print a lightweight, latticed midsole. This is the same technology used to manufacture the midsoles of Adidas 4D Futurecraft shoes.

The youngest of three boys, Imre is extremely athletic and has a smile that lights up every room he walks into. His eagerness to embrace life one step at a time led his family to look at 3D printing as a possible solution to improve their son’s quality of life. A family friend connected the Pattersons with Dinsmore Inc.’s 3D Printing and Additive Manufacturing services in Irvine, California. After meeting Imre, the team immediately started working on a 3D printed solution to help him do all the things he loves to do. The best solution at the time of the first shoe’s design involved using nylon based PA12 material and HP’s Multi Jet Fusion (MJF) Technology. This process uses an array of inkjets that apply fusing and detailing agents to selectively melt fine grains of powder, combining it with a binding agent and heat to form the shape of the latticed midsole. Although this shoe was durable and lighter than his manufactured foam boot, a second round of shoes was needed to keep up with Imre’s active lifestyle.

Carbon’s Digital Light Synthesis™ (DLS) technology was considered for the second version of Imre’s shoes, because of its ability to 3D print the midsole using elastomeric polyurethane based material. This material would provide Imre with a durable, lightweight, and responsive midsole. DLS used light to shape the liquid material in the form of a lattice, forming the midsole specifically in the shape of each shoe it was bonded to. In order to fit all these components together, the shoes provided by Chris Hillyer at Deckers Brands were 3D scanned by Conner Morris at the SEMA Garage. Using the scan data, the Dinsmore team was able to design the CAD model and shape of each 3D printed midsole to fit the specific TEVA and UGG shoes that they were bonded to.

Production Development Engineer at Carbon, Jason Lopes assisted with designing the lattice structure specifically for the technology commented that “as he grows bigger, we can put a scale model on it.” Because the midsoles were designed digitally, “as Imre grows, we can take the baseline of what we’ve already done, modify that lattice structure, and create another midsole,” according to Jay Dinsmore, the Founder and CEO of Dinsmore Inc. One of the benefits of 3D printing is its ability to design upon previous data and adapt it to whatever necessary changes need to be made in the application. Both Imre and his family are actively involved with Dinsmore Inc.’s 3D printing experts to create solutions for Imre as he strides into a future as bright as his smile.

About Dinsmore Inc.

Dinsmore Inc. was founded by Jay Dinsmore, a winner of the 2019 Distinguished Innovator Operators Award (DINO) and an outspoken advocate and educator for Additive Manufacturing and 3D Printing technologies. Dinsmore Inc. has over twenty five years of experience in the industry, and is committed to supporting customers throughout their product design and production journey with technologies from Carbon DLS (Digital Light Synthesis), SLA (Stereolithography), HP’s MJF (Multi Jet Fusion), FDM (Fused Deposition Modeling), Polyjet, and more.

Dinsmore Inc.’s Show Activities

Dinsmore Inc. will be exhibiting at several shows in 2020

MD&M West on February 11-16 in Booth #1872 at the Anaheim Convention Center (Anaheim, CA).

AMUG Conference 2020 on March 22-26 in Booth #P5 at the Hilton Chicago (Chicago, IL).

RAPID + TCT on April 20-23 in Booth #1216 at the Anaheim Convention Center (Anaheim, CA).


Jay Dinsmore
Dinsmore Inc. 714-641-7111
Email: [email protected]