Traditional custom insoles rely on manual measurement and plaster impressions, requiring 45-60 minutes per session and with an error rate of ±3mm.
Modern plantar 3D scanners, however, utilize laser/infrared technology to complete submillimeter-level scans in 90 seconds, with an error rate of ±0.5mm. This technological evolution not only improves product precision but also reshapes the cost model of the entire industry chain.
1. Direct Cost Reduction Effect
Labor Cost Reduction
The traditional process requires specialized technicians to complete processes such as measurement and mold making, with labor costs accounting for 42% of total costs. 3D scanning enables fully automated data collection, reducing labor costs per service by 76%, with technicians only needing to review the final plan.
Scanned data can be directly integrated into CAD design systems, eliminating the repetitive labor associated with traditional mold making. Clinical data from one clinic showed that the use of scanning technology increased daily order volume from 8 to 25 cases.
Optimized Material Loss
Plaster impressions cost an average of 18 yuan per session and are not reusable. Digital models generated by 3D scanning can be used endlessly, reducing material costs to zero.
II. Operational Efficiency Improvement
Production Cycle Revolution
The complete cycle from measurement to delivery has been shortened from the traditional 5-7 days to within 24 hours. After adopting the scanner, one chain store reduced the median customer wait time from 136 hours to 18 hours.
Cloud storage of scanned data allows for remote access, enabling “one-time measurement, lifetime customization” service and improving repeat order processing time by 83%.
Equipment Synergy
3D scan data can directly drive 3D printers or CNC engraving machines, eliminating data conversion losses. Compared to standalone systems, this synergy reduces the defective rate from 12% to 1.8%.
When the scanner is integrated with the thermoforming machine, energy consumption per pair of insoles is reduced by 31% (from 0.78 kWh to 0.54 kWh).
III. Long-Term Marginal Benefits
Precision Medicine Value
Scanning data can identify early-stage pathology such as arch collapse, enabling preventive orthotics and reducing subsequent treatment costs by 57%. Statistics from a rehabilitation institution show that users of scan-based custom insoles see an average reduction of 2,120 yuan in annual medical expenses.
Equipment Depreciation Advantages
Based on a three-year depreciation cycle, the cost per use of a 120,000 yuan scanner is only 3.5 yuan (based on an average of 20 scans per day). Compared to the annual maintenance cost of traditional measurement equipment (12,000 yuan), scanner operation and maintenance costs are reduced by 64%.
Data Asset Value-Added
The foot database can be used to generate value-added services such as gait analysis and sports injury prediction, with near-zero marginal costs. One brand has increased its average order value by 138% through data services.
3D scanning technology transforms custom insoles from labor-intensive to technology-intensive, reducing the combined cost per pair from the traditional 89 yuan to 38 yuan.
This cost advantage is driving the industry’s transformation from a medical assistive device to a mass consumer product. Continuous technological iteration will further enhance the economies of scale of scanning equipment, ultimately achieving universal access to “precision health.”
