Fyous Partners with Renace to Revolutionise Diabetic Footwear Manufacturing

The trial involved 22 pairs of shoes—each made with identical uppers. Eleven of these pairs were fitted with Fyous outsoles using PolyMorphic tooling, while the other eleven pairs were fitted with traditional EVA outsoles. This like-for-like comparison allowed both teams to directly evaluate the differences in production, performance, and overall quality between the two approaches.

Renace approached Fyous with a specific goal in mind—to explore technology that could transform the way they produced diabetic footwear by reducing waste, cutting down on manual work, and improving overall design repeatability. With Fyous's PolyMorphic tooling technology used in a moulding application, they found an innovative solution that could reshape their manufacturing processes entirely.

Traditionally, the production of custom diabetic footwear has been reliant on skilled manual labour. Every pair of shoes was essentially one-of-a-kind, requiring a lot of time and effort to shape, rework, and adjust. As a result, when clinicians issued repeat prescriptions, there was often a struggle to recreate the exact same shoe again, leading to rework and an increased risk of a failed fit. Such inconsistencies meant frustration for both patients and the clinical team.

Fyous offers a novel approach through its PolyMorphic tooling technology. This innovative system allows Renace to create bespoke yet reusable moulds for making PU outsoles—similar to the CAD/CAM processes commonly used to manufacture custom insoles. The result is a moulding solution that not only speeds up production but also offers greater repeatability, reduced waste, and much more flexibility in design.

One of the most compelling advantages of PolyMorphic tooling is its repeatability. Unlike manual processes that rely heavily on artisan skills, the PolyMorphic system allows for consistent reproduction of the same design without the need for labour-intensive craftsmanship. This means that when a diabetic patient requires another pair of shoes, Renace can produce an identical pair every time with minimal effort—dramatically improving the patient experience.

The flexibility of design is another key advantage. With the ability to create custom, one-off moulds that can be adjusted digitally using CAD tools, Renace has a new level of creative freedom when designing their footwear. Instead of being limited by the confines of labour-intensive mould creation, new designs can be produced faster and with fewer constraints. The ability to use CAD to shape, adjust, and optimise designs translates directly into products that fit better, function well, and enhance comfort for the wearer.

Fyous's technology also addresses sustainability concerns. PolyMorphic moulding is inherently designed to be a zero-waste solution. Traditional manual moulding techniques often lead to a significant amount of scrap material, especially when adjustments are needed. In contrast, the PolyMorphic tooling system is built on principles of efficiency, meaning material use is optimised, and the need for multiple single-use moulds is eliminated—a major advantage in an industry increasingly concerned with its environmental footprint.

The partnership between Fyous and Renace is a great example of how advanced manufacturing technologies are reshaping traditional industries. By working together, these two companies are finding a way to merge modern, tech-driven solutions with the compassionate, patient-focused goals that have always driven the orthopaedic footwear market.

With the trial complete, diabetic footwear manufacturers can see the proof in the pudding. With Fyous's PolyMorphic tooling, Renace is seeing firsthand the potential for reduced labour costs, repeatable, high-quality designs, and a drastic reduction in waste. Now, we just need to match outsole design to upper design ;-)

Methodology: How Fyous PolyMorphic System Works

1. Design the Outsole: Design the outsole based on the measurements of the upper and foot.
2. Create the Mould in CAD: Make a mould in CAD by subtracting the original design.
3. Export to STL File: Export that mould CAD file to an STL file.
4. Import to Fyous PinPoint Software: Import the STL file to Fyous PinPoint software to create the PolyMorphic forming machine data file.
5. Form PolyMorphic Tooling: Use the PolyMorphic forming machine to form the tooling.
6. Vacuum Form Protective Membrane: Vacuum form a protective membrane over the tools.
7. Use in Press: Use the PolyMorphic tooling in a press to produce the final outsole.

Before and After Comparisons

You can see in the photos a shoe made using the traditional approach where the EVA outsole is cut from a sheet, bonded to the base of the upper, and then trimmed and sanded to fit. This traditional method results in significant material waste and requires a great deal of manual labour to achieve a reasonable fit.

Traditional approach using EVA

In contrast, the Fyous outsole is moulded using PolyMorphic technology. The result has minimal waste in comparison, as the moulding process allows for a precise fit without the need for extensive trimming or sanding. The efficiency of this method not only reduces waste but also ensures a consistent, high-quality finish with far fewer manual interventions needed. This difference in approach demonstrates the substantial advantages of Fyous's technology in terms of sustainability, efficiency, and repeatability.

Fyous approach using PolyMorphic tooling