This project investigates the use of additive manufacturing (3D printing), specifically Fused Deposition Modeling (FDM), to create custom thermoplastic objects, with a focus on foaming thermoplastic polyurethane (TPU) material. By varying printing temperatures to control porosity, the project aims to test and compare the compressive properties of the material, ultimately exploring the potential to design custom 3D-printed insoles, if time permits. The goal is to create insoles with varying density and compression strength, making them lighter and more cost-effective while providing cushioning benefits. This approach has applications across industries like aerospace and healthcare, aligning with Jabil’s objectives of improving manufacturing efficiency and reducing costs. The production of 3D-printed insoles begins with personalized foot scans to create tailored designs, and the insoles are printed using flexible TPU materials, allowing for precise customization and functionality testing. This technology supports the growing demand for personalized, sustainable solutions in healthcare and orthotics, particularly for conditions like diabetes and pediatric needs. With the use of an instron and durometer, sample testing will adhere to ASTM standards (D695 and D2240) and will focus on porosity, hardness, and compressive strength. The project also includes research into materials, filament selection, and establishing printing standards, with potential applications for customized insole design and pressure mapping.