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CAD-CAM Milling Orthotic Blocks

Introducing our premium range of EVA Foam Blocks, designed specifically for creating custom orthotic insoles using precision CNC milling. These blocks are made from high-quality EVA (Ethylene Vinyl Acetate). This material is durable, flexible and lightweight. It provides a great base for custom orthotic solutions.

Our EVA foam comes in a variety of colours, densities and sizes to meet the diverse needs of podiatrists, orthotists, technicians and healthcare professionals. With options ranging from soft to firm densities, you can customise the support level - ensuring each orthotic is perfectly matched to the individual’s requirements. The availability of various colours also allows for easy identification and differentiation between materials, helping streamline your manufacturing process.

CAD-CAM Milling Orthotic Blocks

EVA Foam


Algeos Custom EVA Foam Cutting Service
for Orthotic Labs and Industry

EVA (Ethylene Vinyl Acetate) foam is widely recognised for its versatility and effectiveness across various industries, particularly in orthotic applications where comfort, durability and support are paramount. Algeos offers a complete custom EVA foam cutting service. This service is designed for orthotic labs and other industries. We focus on providing precise, high-quality EVA foam parts. With the ability to cater to different densities, colours, thicknesses and custom shapes, our service is designed to support businesses in creating products that align with exact specifications and performance expectations.

A Tailored Approach to EVA Foam Cutting

Every application is unique, and understanding the precise needs of each client is at the heart of our custom EVA foam cutting service. Orthotic labs, in particular, require materials that can be adapted to accommodate a diverse range of foot conditions and orthotic solutions. EVA foam’s adaptability is ideal for this purpose, as it can be shaped, layered and designed to offer specific levels of cushioning and support for individuals’ needs.

Our custom cutting service ensures that each piece of EVA foam is tailored exactly to the dimensions and shapes required by our clients, whether for orthotics, padding, footwear components, or other applications. By providing foam in different densities, we allow customers to choose materials that match the required firmness or softness for their specific products, ensuring maximum comfort and performance.

Diverse Densities for Versatile Applications

One of the major advantages of our EVA foam cutting service is the option to select from various densities. Density plays a crucial role in how the foam performs in different applications. Lower-density EVA foam is often chosen for applications requiring a softer, more flexible material, such as cushioning layers in orthotics or shock-absorbing inserts. Conversely, higher-density EVA foam is more suited to structural support or high-wear components, providing a more robust and durable solution.

For orthotic labs, selecting the correct density can make a significant difference in how well an orthotic device functions, particularly when it comes to managing load-bearing areas, redistributing pressure, and minimising the risk of discomfort or injury. Our range of densities allows labs and other industries to select the perfect material for their specific needs.

A Spectrum of Colours for Branding and Identification

Colour choice may seem like a minor detail, but it can play an important role in product differentiation, branding, and even functionality. At Algeos, we offer EVA foam in a wide spectrum of colours to meet the branding or visual needs of our clients. In orthotic labs, different colours can help with the easy identification of various density foams or layers within an orthotic device, making assembly and quality control more efficient.

For industries such as footwear manufacturing, coloured EVA foam can enhance brand aesthetics and distinguish between different product lines or models. This flexibility supports both practical and aesthetic considerations, enabling clients to create a cohesive and visually appealing product range.

Precision Thicknesses for Optimal Performance

EVA foam thickness is another essential variable, as it determines the cushioning and durability of the final product. Algeos offers custom-cut EVA foam in a variety of thicknesses, providing clients with the flexibility to create products that meet specific performance requirements. For instance, thicker foam is often used in applications requiring additional cushioning or insulation, while thinner foam is suitable for applications where flexibility and low profile are prioritised.

Our cutting technology ensures that each piece of foam is precisely cut to the required thickness, minimising waste and ensuring a consistent final product. This precision is especially valuable in orthotic labs, where even slight variations in thickness can affect the fit and effectiveness of an orthotic device.

Custom Shape Cutting with Die Cutters

One of the defining features of Algeos’ custom EVA foam cutting service is our capability to create foam components in any shape required. Using advanced die cutters, we can produce complex shapes that fit seamlessly into the final product design. Die cutting is a highly efficient and accurate process, ideal for large-scale production as well as custom one-off projects. This capability is invaluable for orthotic labs, where intricate shapes may be needed to fit specific foot contours or to achieve a precise biomechanical outcome.

Industries beyond orthotics can also benefit from this custom shape-cutting service. For example, the automotive industry may require custom-shaped foam inserts for interior components, while the sports equipment industry can use custom EVA foam shapes for protective padding and shock absorption. Our die-cutting service enables clients across multiple sectors to receive foam components that meet their exact design and functional requirements.

Why Choose Algeos?

Algeos’ commitment to quality, precision, and flexibility makes our custom EVA foam cutting service a trusted choice for orthotic labs and various other industries. Our ability to offer custom densities, colours, thicknesses, and shapes ensures that each client receives EVA foam components that align with their product goals. This tailored approach supports innovation and efficiency, empowering businesses to create products that stand out in terms of performance, durability, and aesthetics.

From orthotic devices to automotive interiors, our custom EVA foam cutting service is here to support diverse industries with solutions that are as unique as their applications.

To request a custom quotation, please contact us with your exact requirements.