PureSole – Technology and development

PureSole is the largest new series of orthotic blanks produced at the Zeulenroda Technology Department in more than ten years. A great deal of development work went into the new models – from new manufacturing technologies and innovative material concepts all the way to a brand-new last design. Product Developer Peter Schultz played a key role in designing the PureSole Comfort models. In the interview he discusses technical challenges, his personal development philosophy and why he is still enthusiastic about the project.

Peter, if you had to explain PureSole to a colleague from the industry – what’s the first thing you would show them?

Peter Schultz: The new underside of the foot orthosis. Our goal was to develop a blank that required as little preparatory work as possible, while also making work much easier for the orthotist. The new plate pressing method results in a flat, cleanly shaped underside during the manufacturing process. This reduces or entirely eliminates a lot of effort in grinding the blanks for the appropriate footwear. The blank is already very similar to the finished product – and already looks high-quality.

What are the technical innovations in the new blanks?

Peter Schultz: Apart from the new pressing technology, we created a brand-new last. This involves a corrective concept based on the back foot, which integrates many properties into the basic form of the insole. Then there are flatter pads, more room for the tendons and guidance of the heel bone using inner and outer stirrup structures.

Another special feature is the new isobar texture on the surface. This three-dimensional texture improves guidance of the foot, reduces shearing forces and reinforces the insole’s corrective effect. At the same time it lends an independent, modern look.

How did the idea for this texture come about?

Peter Schultz: It was actually a matter of chance. During a 3D printing test for a last in the Bauerfeind Innovation Center, one of the print settings was much coarser than planned. But the result looked exciting. I immediately started thinking about the functional advantages that could be achieved. This was developed step by step to become what is now the isobar texture. Moments like this are often the starting point for new ideas in development.

“A lot of my own philosophy went into it.”
Peter Schultz, Product Developer Foot Orthopedics

Why was the new last concept your personal pet project?

Peter Schultz: A lot of my own philosophy went into it. I have been working on foot orthoses for decades and of course I have ideas about how an orthosis should work. With PureSole, it was the first time I was able to consistently implement a lot of these ideas on a new last. Which is why I also say: This last is my baby.

What are the advantages of having development and production here at Zeulenroda?

Peter Schultz: Proximity. If a question comes up, I just walk a few feet and discuss them directly with my colleagues. That speeds up a lot of processes. Plus we have the entire value chain very closely networked. From material preparation to thermoforming all the way to final inspection, everything happens on one level. This allows us to quickly test new ideas, get feedback and directly implement any improvements.

What was the collaboration like with your colleagues in the Production Department?

Peter Schultz: My colleagues shared the responsibility for the project from the very start. Many of them got to see the developments directly in manufacturing and wanted to know what was coming next. There was a great deal of interest, and this resulted in real enthusiasm.

Our manufacturing depends on versatility. We work with many different materials, methods and product variants. And that’s precisely what makes our work exciting. At the same time, my colleagues are very flexible and know how to manage multiple work steps. This is a huge help when you’re executing a project of this magnitude.

Looking back on PureSole, what makes you particularly proud?

Peter Schultz: The fact that we were able to contribute so many new ideas. A lot of them had been on my mind for a long time already. And now we finally got the chance to make them a reality. Which is always a lot of fun. That’s why I became a developer.

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PureSole – Technology and development

How ideas become innovations