The Problem

Traditional orthotics live as add-ons: removable inserts that often feel bulky, restrictive, or incompatible with modern footwear. The client's geometry worked in the clinic. It now had to be translated into everyday footwear, something people would actually choose to wear. The question was simple to ask and hard to answer: how do you embed true medical-grade function directly into a shoe without sacrificing comfort, aesthetics, or scalability?

Instead of treating the orthotic as an afterthought, the patented geometry was engineered directly into the last and midsole — so the biomechanical benefit became structural, not dependent on an insert.
The Approach

Rethinking the shoe's foundation meant an iterative cycle of prototyping, refining, and pressure-testing. A balance of geometry and materials against rote production and the demands of daily wear.

3D CAD model of the engineered last and midsole geometry
Validation Through Wear Testing

Multiple rounds of real-world wear testing gathered feedback to validate not just comfort, but efficacy. Each iteration informed adjustments to tooling, foam compounds, and construction methods, while preserving the original clinical intent.

Grid of real on-foot wear-test photographs of the Project NZ sneaker in multiple settings
Sourcing & Production

On the production side, sourcing the right partner was critical. The design was brought to commercial scale with a factory in Portugal, known for its craftsmanship and technical capability — aligning on tooling precision, material selection, and quality control standards to preserve the integrity of the embedded geometry throughout manufacturing.

The Result

A casual shoe that delivers the benefits of a patented orthotic system without looking or feeling like a medical device. This is a product that bridges the gap between healthcare and lifestyle, grounded in science, validated through testing, and realized through engineering and global sourcing.

Working on something with a similar arc?

Concept, technical development, and sourcing — handled by one partner instead of three vendors who don't talk to each other.

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