3D CAD Engineer — Custom Shoe Insole with Variable-Density Lattice for SLS & FDM 3D Printing

We're a luxury sneaker startup (Blue Soul Shoes) building made-to-order shoes for men with wide feet (W, 2E, 4E, 6E+). We need a CAD engineer to take our Italian-designed shoe component files (STL/STEP/IGES) and: Fix meshes — repair open edges, non-manifold geometry, and solidify surfaces on our outsole, shoe last, and insole files Design a variable-density honeycomb/lattice insole — 5 zones (heel, arch, forefoot, toe, lateral) with different lattice densities to control firmness. Denser = firmer, sparser = softer. Must support 3 arch profiles (flat, medium, high) and left/right mirroring. Create a parametric template — insole must be parametric (Fusion 360, Rhino/Grasshopper, or SolidWorks) so we can adjust foot length, ball width, arch height, arch type, and L/R per customer. We're made-to-order — any size, any width. Two printing processes (design must work for both): SLS (production): Outsourced, nylon PA11/PA12. No build volume constraint. This is how customer orders are fulfilled. FDM (prototyping): In-house Bambu Lab H2C, TPU 90A, 256×256×256mm bed. For rapid iteration. Source files (all size US 10.5 base): Outsole STL: 311×117×28mm, 110K tris, nearly watertight Shoe last STL: 297×102×108mm, 95K tris, needs full repair (7K+ open edges) Insole STL + IGES + STEP: 297×103×14mm, open surfaces — needs solidifying Lattice Zone Map: Heel (rear 30%): Soft cushion, 30-40% density, 5-6mm cells Arch (medial midfoot): Firm support, 60-70% density, 3-4mm cells Forefoot (front 35%): Responsive, 45-55% density, 4-5mm cells Toe (front 10%): Flexible, 25-35% density, 5-6mm cells Lateral (outside rim): Stable, 55-65% density, 3-4mm cells Lattice visible from sides (design feature). Solid top skin 0.8-1.2mm for comfort. Deliverables: Repaired/solidified insole with lattice structure (3 arch profiles × L/R) Repaired outsole (split version for FDM + full version for SLS) Repaired shoe last mesh Parametric template accepting continuous size/width inputs All files as watertight STL + native CAD format Budget: $500–$1,500 (fixed-price preferred) Timeline: 2–3 weeks M1 (~$300-500): Mesh repairs + insole solidified M2 (~$400-600): Lattice design for 3 arch profiles + L/R M3 (~$200-400): Parametric template + final STLs Ideal candidate: Experience with Rhino/Grasshopper, Fusion 360, or nTopology 3D-printed insole, orthotic, or footwear work Understands SLS nylon AND FDM TPU constraints Lattice/honeycomb design for variable mechanical properties To apply: Include (1) lattice/honeycomb examples, (2) your CAD software choice, (3) SLS or TPU printing experience, and (4) your approach to making the insole parametric. Start your proposal with "BLUE" so we know you read this. We have a detailed technical reference document (file analysis, size/width charts, arch type specs, automated pipeline vision) that we'll share with the selected freelancer.