This poster presents a method for designing and manufacturing custom orthotic insoles for diabetic patients using advanced technologies. The computer-aided reverse engineering system (CARESystem) was employed to reduce errors from foot scans. DICOM images from HandySCANN 700 TM were converted into stereolithography (STL) files, which were then refined using VXElement and Geomagic software for accurate STL data. The orthotic shoe (insole and outsole) was modeled with curve-based surface modeling (CBS) and smoothed before CNC milling. The CNC milling process, crucial in modern manufacturing, involves optimizing cutting conditions and process irregularities to achieve low surface roughness (Ra). The Taguchi method combined with response surface methodology (RSM) effectively determined optimal parameters. Analysis showed the dimensional deviation averaged less than 1 mm, demonstrating the method's effectiveness in providing custom orthotics with high accuracy and comfort.