Has anyone tried printing rigid insoles with Tough 1500 V2 resin?

Experimental
1

Hi everyone,

Has anyone tested Tough 1500 V2 for printing orthopedic or rigid insoles? I’m currently experimenting on a Form 4L and looking for feedback on its mechanical performance under repeated flexing.

I’m trying to achieve a balance between rigidity and resistance to cracking (Ross flex fatigue). So far, small test pieces perform well, but I’m concerned about long-term use where the insole bends thousands of times.

A few specific questions:

How has Tough 1500 V2 held up in cyclic bending or localized stress zones?

Any post-cure adjustments or design modifications (lattice, variable thickness, relief channels) that improved performance?

Has anyone compared results with Durable, Elastic 50A, or Loctite resins for similar applications?

Appreciate any insights, photos, or workflow details that could help optimize this use case.

Thanks!

2

Are you intending on having the insole be the length of the foot, or from heel to arch? If it is the length of the foot there will be some decent strain in the material where it bends between the ball of your foot and toes that I suspect will break the material pretty quickly, else the material would be so rigid it would be very unpleasant to walk or run in. Below the arch only I don’t think there would be much deflection of the material itself, so it should hold up alright. Tough1500 v2 has similar material properties to PP which is a common material for orthotics. Formlabs did some similar work with TPU90A of the Fuse1 you can reference as well.

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