Personalized customized insole manufacturing method

Abstract

The invention provides a personalized customized insole manufacturing method, which is characterized by comprising the following steps of: performing omnibearing scanning on both feet of a user by adopting a 3D (three-dimensional) foot shape scanner to obtain detailed foot shape data; importing the collected data into software to generate a three-dimensional contour model, and marking key points; according to the data and the analysis result, designing a three-dimensional insole model conforming to the user; selecting a flexible material suitable for the insole; importing the designed three-dimensional insole model into a 3D printer; proper printing parameters are set, the 3D machine is started, and materials are stacked layer by layer until printing is completed; after printing is completed, the temporary supporting structure is removed, and the surface of the insole is polished; and performing quality inspection to ensure that the size, the shape and the performance of the insole meet the design requirements. By means of the steps, shoe pad customization of the user can be efficiently completed, the cost can be saved, various requirements of the user can be met, generated waste materials are few, and the influence on the environment is small.

Description

Technical Field

[0001] The invention relates to the field of footwear product manufacturing, and in particular to a method for manufacturing a personalized customized insole. Background Art

[0002] In modern life, people have put forward higher and higher requirements for the comfort and health of shoes. As an important part of shoes, insoles directly affect the comfort and foot health of the wearer. Traditional insoles are usually standardized products produced in batches. Although they can meet the needs of general users, they cannot fully take into account the uniqueness of each person's foot shape. Therefore, many people feel uncomfortable after walking or exercising for a long time, and even have problems such as foot pain and arch collapse. Therefore, there is a demand in the market for personalized customized insoles that better fit individual foot shapes and provide better support and comfort.

[0003] However, the existing method for manufacturing personalized insoles has the following problems: High cost: Existing methods for manufacturing personalized custom insoles usually rely on complex mold manufacturing and manual adjustments, which leads to high production costs and limits their widespread application.

[0004] Long production cycle: From foot shape data collection to final product delivery, the entire process needs to go through multiple links, including data processing, mold manufacturing, manual adjustment, etc. The production cycle is long and cannot meet the needs of rapid response to the market.

[0005] Limited material selection: Traditional manufacturing methods are relatively single in material selection, and it is difficult to meet the diverse needs of different users for insole performance.

[0006] Precision and consistency issues: Errors are prone to occur during manual adjustment and mold manufacturing, making it difficult to ensure the precision and consistency of the final product.

[0007] Environmental impact: The traditional manufacturing process produces a lot of waste, which is not conducive to environmental protection and sustainable development. Therefore, an efficient and cost-effective method for manufacturing personalized customized insoles is needed. Summary of the invention

[0008] In view of the shortcomings of the background technology, the present invention provides a method for manufacturing a personalized customized insole to provide users with a more comfortable and healthy insole solution.

[0009] Technical Solution The method for manufacturing a personalized custom insole of the present invention comprises the following steps: Foot data collection: (a) Use a high-precision 3D foot scanner to perform a full-scale scan of the user's feet to obtain detailed foot shape data. Foot shape data includes but is not limited to foot length, foot width, arch height and sole pressure distribution. The sole pressure distribution can be obtained through the foot pressure distribution measurement system.

[0010] Data processing and analysis: (b) Import the collected foot shape data into computer-aided design (CAD) software.

[0011] The data is processed to generate a three-dimensional contour model of the sole of the foot and mark key points such as the toes, heels, arches, etc.

[0012] Analyzes pressure distribution on the sole of the foot to identify areas that require additional support or cushioning and marks these areas on a 3D contour model.

[0013] Personalized design: (c) Based on the user’s foot shape data and analysis results, a three-dimensional insole model that conforms to the user’s foot shape is designed.

[0014] During the design process, user-preferred features can be incorporated, such as strengthening support in certain areas, adding ventilation holes, and adjusting the thickness or hardness of the insole to meet the specific needs of users.

[0015] By adjusting the parameters in the model (such as thickness, hardness, density, etc.), the comfort and functionality of the insole can be optimized.

[0016] 3D printing material selection: (d) Select flexible materials suitable for insoles, such as thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), etc.

[0017] TPU material has high elasticity and good shock-absorbing performance, and TPE material has good flexibility and wear resistance.

[0018] According to the specific needs of users (such as sports, daily walking, etc.), choose materials with appropriate hardness and elasticity. For example, for users who need more support, choose materials with higher hardness, and for users who need more shock absorption, choose materials with better elasticity.

[0019] 3D printing manufacturing: (e) Import the designed three-dimensional insole model into the 3D printer.

[0020] (f) Setting appropriate printing parameters, such as layer thickness between 0.1 mm and 0.5 mm, filling density between 50% and 90%, and printing speed between 20 mm / s and 100 mm / s.

[0021] A printing mode is selected, wherein the printing mode is selected from at least one of a standard mode, a high-speed mode or a high-precision mode, wherein the standard mode is suitable for printing conventional insoles, the high-speed mode is suitable for mass production, and the high-precision mode is suitable for customized insoles requiring extremely high precision.

[0022] The 3D printing process is started, and the material is stacked layer by layer until the entire insole is printed.

[0023] Post-processing: (g) After printing is complete, remove any temporary support structures.

[0024] Polish the surface of the insole, use sandpaper or a grinder to remove the rough parts of the surface, ensure that the surface of the insole is smooth and flat, and improve wearing comfort.

[0025] (h) Clean the insole. Use clean water or a special cleaning agent to remove any fine particles that may remain during the printing process and ensure that the surface of the insole is clean and free of contamination.

[0026] Quality Inspection: (i) Ensure that the size, shape and performance of the insole meet the design requirements through size inspection, shape matching and performance testing.

[0027] Performance tests include hardness testing, elasticity testing and durability testing.

[0028] (j) Packaging and Delivery: The insoles that have passed the inspection shall be packed individually or in pairs in moisture-proof bags or sealed bags.

[0029] Mark the user's personal information on the label, including name, contact information and order number, to facilitate subsequent delivery and after-sales service.

[0030] The present invention has the following beneficial effects: Personalized fit: Through precise foot shape data and personalized design, the insole can perfectly fit the user's foot shape, providing excellent comfort and support.

[0031] Efficient production: 3D printing technology greatly shortens the manufacturing cycle from design to finished product and improves production efficiency.

[0032] Cost savings: 3D printing technology reduces reliance on complex molds and manual adjustments, while reducing material waste in the traditional manufacturing process, thereby reducing production costs and making personalized customized insoles more popular.

[0033] Promote sustainable development: 3D printing technology uses almost only the required amount of material, reducing waste generation and meeting the requirements of environmental protection and sustainable development.

[0034] Improved precision and consistency: 3D printing technology can precisely control the stacking of each layer of material, ensuring the consistency of the size, shape and performance of the final product.

[0035] Diverse choices: Users can choose different materials and design features according to their needs to meet diverse market demands. DETAILED DESCRIPTION

[0036] Assuming that the user is an athlete who often runs and needs a customized insole with good shock-absorbing performance, the user can use the present invention, i.e., "a method for manufacturing personalized customized insoles based on 3D printing technology" to manufacture the required customized insoles. The specific steps are as follows: Foot data collection: Use a high-precision 3D foot scanner (such as Artec Eva or HP ScanJet Pro 4500) to scan the user's feet in all directions to obtain detailed foot data. During the scanning process, the user needs to stand on the scanning platform and maintain a natural standing posture.

[0037] The collected data include foot length, foot width, arch height and sole pressure distribution. The sole pressure distribution is obtained by a foot pressure distribution measurement system (such as Tekscan F-Scan).

[0038] Data processing and analysis: Import the collected foot shape data into computer-aided design (CAD) software (such as Autodesk Fusion 360 or SolidWorks), generate a three-dimensional contour model of the sole of the foot in the CAD software, and mark key points such as the toes, heels, arches, etc.

[0039] Analyzes the pressure distribution on the sole of the foot, identifies areas that require additional support or cushioning, and marks these areas on the 3D contour model. For example, if the user experiences greater pressure in the heel and forefoot areas when running, these areas are marked as requiring additional support.

[0040] Personalized design: Based on the user's foot shape data and analysis results, a three-dimensional insole model that conforms to the user's foot shape is designed.

[0041] During the design process, user-preferred features are incorporated, such as enhanced support in the heel and forefoot areas to provide better cushioning.

[0042] Perforations are designed in the arch area to increase breathability.

[0043] Adjust the thickness of the insole, for example adding more thickness at the heel for better cushioning.

[0044] Adjust the firmness of your insoles, such as using softer material around the arch of your foot to improve comfort.

[0045] The comfort and functionality of the insole can be optimized by adjusting the parameters in the model, such as thickness, hardness, density, etc. For example, the thickness is set to 10 mm and the hardness is set to Shore A 50.

[0046] 3D printing material selection: Choose a flexible material suitable for insoles, such as thermoplastic polyurethane (TPU) or thermoplastic elastomer (TPE).

[0047] Since the user is an athlete who runs frequently, a TPU material with high elasticity and good shock-absorbing properties is selected, such as a TPU material with a Shore A hardness of 50.

[0048] In short, you can choose materials with appropriate hardness and elasticity according to the specific needs of users. For users who need more support, choose materials with higher hardness, and for users who need more shock absorption, choose materials with better elasticity.

[0049] 3D Printing Manufacturing: Import the designed 3D insole model into a 3D printer (such as Formlabs Form Ⅲ or Stratasys J750).

[0050] Set appropriate printing parameters: The layer thickness was set to 0.1 mm to ensure printing accuracy.

[0051] The filling density is set at 80% to ensure the strength and elasticity of the insole.

[0052] The printing speed was set to 60 mm / s to balance printing time and quality.

[0053] Select high-precision mode for printing to ensure the detail and surface quality of the insole.

[0054] The 3D printing process is started, and the material is stacked layer by layer until the entire insole is printed.

[0055] Post-processing: After printing is complete, remove any temporary support structures. Use pliers or a specialized tool to carefully remove the support structures to avoid damaging the surface of the insole.

[0056] Polish the surface of the insole, use sandpaper (such as P400 sandpaper) or a grinder (such as a Dremel grinder) to remove the rough parts of the surface to ensure that the surface of the insole is smooth and flat to improve wearing comfort.

[0057] Clean the insole and use clean water or a special cleaning agent (such as IPA alcohol) to remove the fine particles that may remain during the printing process to ensure that the surface of the insole is clean and free of pollution.

[0058] Quality Inspection: Through size inspection, use calipers or a 3D measuring machine (such as the Faro Arm) to measure the length, width and thickness of the insole to ensure that the size meets the design requirements.

[0059] Through shape matching, the insole is compared with the user's foot shape data to ensure the shape is consistent.

[0060] To perform performance testing: Hardness test: Use a Shore durometer (such as Shore A durometer) to test the hardness of the insole to ensure that the hardness meets the design requirements.

[0061] Elasticity test: Use a universal testing machine (such as Instron 5969) to test the elastic recovery rate of the insole to ensure that the elastic performance meets the design requirements.

[0062] Durability testing: Testing the durability of the insole using a fatigue testing machine (such as the MTS Criterion) ensures that the insole will continue to perform well after repeated use.

[0063] Packaging and Delivery: The insoles that pass the inspection will be packaged individually or in pairs, and packed in moisture-proof bags or sealed bags to prevent moisture and contamination.

[0064] Mark the user's personal information on the label, including name, contact information and order number, to facilitate subsequent delivery and after-sales service.

[0065] After preparation, the insoles will be delivered to the user via express delivery or other means.

[0066] In summary, the present invention has the following beneficial effects: Personalized fit: Through precise foot shape data and personalized design, the insole can perfectly fit the user's foot shape, providing excellent comfort and support.

[0067] Efficient production: 3D printing technology greatly shortens the manufacturing cycle from design to finished product and improves production efficiency.

[0068] Cost savings: 3D printing technology reduces reliance on complex molds and manual adjustments, while reducing material waste in the traditional manufacturing process, thereby reducing production costs and making personalized customized insoles more popular.

[0069] Promote sustainable development: 3D printing technology uses almost only the required amount of material, reducing waste generation and meeting the requirements of environmental protection and sustainable development.

[0070] Improved precision and consistency: 3D printing technology can precisely control the stacking of each layer of material, ensuring the consistency of the size, shape and performance of the final product.

[0071] Diverse choices: Users can choose different materials and design features according to their needs to meet diverse market demands.

Claims

1. A method for manufacturing a personalized custom insole, characterized in that: The following steps are involved: (a) Use a 3D foot scanner to scan the user's feet in all directions to obtain detailed foot shape data; (b) Importing the collected foot shape data into computer-aided design (CAD) software to generate a three-dimensional contour model of the sole and mark the key points; (c) designing a three-dimensional insole model that meets the user's foot shape characteristics based on the user's foot shape data and analysis results; (d) Select flexible materials suitable for insoles; (e) importing the designed three-dimensional insole model into the 3D printer; (f) setting appropriate printing parameters, starting the 3D printing process, and stacking the materials layer by layer until the entire insole is printed; (g) After printing is completed, remove any temporary support structures and polish the surface of the insole; (h) Clean the insole to remove any fine particles that may have remained during the printing process; (i) Conduct quality inspection to ensure that the size, shape and performance of the insoles meet the design requirements; (j) The insoles that pass the inspection will be packaged and the user’s personal information will be marked on the label.

2. The method according to claim 1, characterized in that The foot shape data described in step (a) include foot length, foot width, arch height and sole pressure distribution, wherein the sole pressure distribution is obtained by a foot pressure distribution measurement system.

3. The method according to claim 1, characterized in that Step (b) also includes analyzing the pressure distribution on the sole of the foot to determine areas that require additional support or cushioning and marking these areas in the three-dimensional contour model.

4. The method according to claim 1, characterized in that Step (c) also includes incorporating user-preferred features into the design process, such as enhancing support in certain areas, adding ventilation holes, and adjusting the thickness or hardness of the insole to meet the specific needs of the user.

5. The method according to claim 1, characterized in that The flexible material in step (d) is selected from at least one of thermoplastic polyurethane (TPU) and thermoplastic elastomer (TPE).

6. The method according to claim 1, characterized in that Step (e) also includes selecting a material with appropriate hardness and elasticity according to the specific needs of the user, for example, selecting a material with higher hardness for a user who needs more support, and selecting a material with better elasticity for a user who needs more shock absorption.

7. The method according to claim 1, characterized in that The printing parameters described in step (f) include a layer thickness between 0.1 mm and 0.5 mm, a filling density between 50% and 90%, and a printing speed between 20 mm / s and 100 mm / s, wherein the selection of layer thickness and filling density depends on the expected performance of the insole and the printing time requirements.

8. The method according to claim 1, characterized in that Step (f) also includes selecting a printing mode, wherein the printing mode is selected from at least one of a standard mode, a high-speed mode or a high-precision mode, wherein the standard mode is suitable for printing conventional insoles, the high-speed mode is suitable for mass production, and the high-precision mode is suitable for customized insoles requiring extremely high precision.

9. The method according to claim 1, characterized in that Step (g) also includes grinding the surface of the insole, using sandpaper or a grinder to remove rough parts of the surface, ensuring that the surface of the insole is smooth and flat, thereby improving wearing comfort.

10. The method according to claim 1, characterized in that Step (i) also includes quality inspection to ensure that the size, shape and performance of the insole meet the design requirements through size detection, shape matching and performance testing, wherein the performance test includes hardness test, elasticity test and durability test.