A 3D printing-based elastic support insole for pregnant women and a personalized customization method

Abstract

The application discloses a 3D printing-based elastic supporting insole for pregnant women and a personalized customization method, and the insole is composed of an elastic matrix integrally formed through 3D printing and a foamed memory foam flexible surface layer combined on the top surface of the elastic matrix. The elastic matrix is designed with regionalized heterogeneous lattices according to the biomechanical characteristics of the foot in the gestation period. Gyroid three-periodic minimal surface lattices are arranged in the instep area, Voronoi tessellation polygon lattices are arranged in the high-pressure areas of the heel and the first and second metatarsal bones of the forefoot, and regular honeycomb structures are arranged in the non-main pressure-bearing areas to realize light weight. Rotating square honeycomb lattices are arranged on the side walls and the bottom periphery. The elastic matrix is provided with an inner-high and outer-low wedge structure in the forefoot and a heel cup structure adapted to the calcaneus in the heel. The application effectively solves the problems of foot arch collapse, foot pressure concentration, unstable gait and fixed support of the traditional insole during the gestation period, provides a personalized foot support scheme with dynamic adaptation, pressure balance and comfortable fit for pregnant women, and simultaneously relieves adverse reactions caused by abnormal foot mechanics.

Description

Technical Field

[0001] This invention relates to the field of functional insole technology, specifically to a 3D-printed elastic support insole for pregnant women and a method for personalized customization. Background Technology

[0002] During pregnancy, women experience significant morphological and biomechanical changes in their feet due to hormonal changes, weight gain, and shifts in the center of gravity. These changes include a decrease in arch height, an increase in foot length and width, an increase in foot volume, and an overall shift towards pronation. During dynamic walking, plantar pressure exhibits a shift from lower pressure in the hindfoot to higher pressure in the midfoot and forefoot. In late pregnancy, the midfoot becomes the core area of ​​plantar load, and there is a significant asymmetry in pressure distribution between the left and right feet. This increased tendency towards pronation is also significantly associated with the occurrence of lower back pain during pregnancy.

[0003] Traditional arch support insoles often use a solid, high-rigidity fixed support structure to passively lift the arch and alleviate collapse symptoms. This design restricts the natural compression-rebound dynamic movement of the arch during the gait cycle and cannot adapt to the continuous changes in foot shape during pregnancy. At the same time, traditional insoles are mostly manufactured in a standardized manner, making it difficult to achieve precise customization for individual foot geometry and pressure distribution characteristics. This can easily lead to local pressure concentration on the sole of the foot, aggravating lower limb alignment abnormalities and failing to solve the problem of gait instability during pregnancy.

[0004] Therefore, this invention provides a 3D-printed elastic support insole for pregnant women and a personalized customization method, thereby achieving precise matching of the special foot support needs of pregnant women. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing products and provide a 3D-printed elastic support insole for pregnant women and a personalized customization method. Through regional heterogeneous lattice design, mechanically guided geometric structure design and full-process digital customization, it achieves multiple effects such as dynamic elastic support, precise distribution of foot pressure, adaptive foot wrapping and gait correction, adapting to the dynamic changes of the foot during pregnancy and solving the problems of fixed support, poor adaptability and concentrated pressure of traditional insoles.

[0006] The technical solution adopted by the present invention to solve its technical problem is as follows: The present invention provides a 3D-printed elastic support insole for pregnant women, including an integrated 3D-printed elastic matrix and a flexible surface layer composited on the top surface of the elastic matrix; the interior is provided with a heterogeneous lattice structure according to functional partitions, and the elastic matrix is ​​provided with a wedge-shaped structure with the inner side higher than the outer side in the forefoot area, and a heel cup structure adapted to the physiological curvature of the calcaneus in the heel area.

[0007] Preferably, the lattice functional partitioning of the elastic matrix is ​​as follows: Arch support area: configured as a Gyroid lattice structure with three-period minimal curved surfaces; Shock absorption zone: distributed in the center of the heel and below the first and second metatarsal bones of the forefoot, configured as a Voronoi lattice structure of a Tyson polygon; Lightweight filling area: distributed in non-primary pressure-bearing areas other than the arch support area and impact absorption area, configured as a conventional hexagonal honeycomb lattice structure; Adaptive encapsulation region: distributed on the sidewalls and bottom periphery of the elastic matrix, configured as a rotating square honeycomb lattice structure.

[0008] Preferably, the Gyroid lattice structure of the arch support area has its lattice size and wall thickness adjusted according to the user's arch height data. It can deform and store energy when compressed and rebound quickly after unloading, thus simulating the dynamic support function of a normal arch.

[0009] Preferably, the Voronoi lattice structure of the impact absorption region is a non-uniform gradient design. By adjusting the distribution density of random seed points, the cell wall thickness is increased or the cell cavity size is reduced in the region corresponding to the pressure peak, thereby achieving foot pressure dispersion.

[0010] Preferably, the height difference between the inner and outer sides of the forefoot wedge structure is 2mm to 3mm, and the wedge angle is 3° to 5°, which is used to counteract excessive pronation of the foot and guide the forefoot push-off force point to spread to the entire palm.

[0011] Preferably, the radius of curvature of the concave surface of the heel cup structure is adapted to the physiological curvature of the calcaneus, which is used to stabilize the calcaneus and relieve heel eversion.

[0012] Preferably, the rotating square honeycomb lattice structure of the adaptive wrapping region generates a negative Poisson's ratio effect when compressed, causing the sidewalls to tighten towards the central axis of the foot, and the edges and gaps of the lattice units form fine anti-slip textures.

[0013] Preferably, the flexible surface layer is a foamed memory foam fabric, which can adaptively conform to the contour of the foot, achieve secondary pressure equalization, and serve as a flexible buffer interface between the foot and the elastic substrate.

[0014] Preferably, the elastic matrix is ​​made of foamed PEBA filament and printed using a fused deposition modeling process.

[0015] Meanwhile, this invention provides a 3D-printed elastic support insole for pregnant women and a personalized customization method, including the following steps: S1: Obtain a three-dimensional geometric model of the user's foot under weight-bearing conditions using a three-dimensional foot scanner, and extract characteristic parameters such as arch height, foot length, foot width, and foot circumference; S2: Collect plantar pressure distribution data of users in static standing and dynamic walking states through the plantar pressure analysis system, and identify the pressure peak area, pressure center trajectory and the difference in pressure distribution between the left and right feet; S3: Based on the three-dimensional geometric model of the foot in step one, determine the overall outline of the elastic matrix, the basic shape of the forefoot wedge structure, and the heel cup structure; S4: Based on the plantar pressure distribution data in step two, configure the lattice type, relative density and gradient parameters of each functional zone of the elastic matrix: generate a Gyroid lattice in the arch support zone, generate a Voronoi lattice with density gradient changes in the impact absorption zone, generate a conventional hexagonal honeycomb lattice in the lightweight filling zone, and generate a rotating square honeycomb lattice in the adaptive wrapping zone. S5: Perform Boolean operations on the basic morphological model from step three and the lattice structure model from step four to generate a three-dimensional digital model of the elastic matrix. S6: Import the three-dimensional digital model into a 3D printer and print it in one piece using foamed PEBA filament through fused deposition modeling process to obtain an elastic matrix; S7: After cutting the foamed memory foam fabric, it is laminated to the top surface of the elastic matrix using either an environmentally friendly adhesive or a hot-pressing process. After trimming and cleaning, the finished insole is obtained.

[0016] The beneficial effects of this invention are as follows: 1. This invention features a Gyroid lattice structure in the arch support area of ​​the resilient matrix. Based on the characteristic of decreased arch height in pregnant women, the lattice period and rod diameter are adjusted to induce controllable elastic deformation under pressure and rapid rebound after unloading, providing dynamic lifting support for collapsed arches. A Voronoi lattice structure is used to create a gradient density in the first metatarsal pressure peak area, increasing cell wall thickness compared to surrounding areas, thus dispersing pressure and efficiently absorbing landing impact and extension shear forces. A lightweight filling area is located in non-primary pressure-bearing areas such as the outer arch and midfoot, featuring a conventional hexagonal honeycomb lattice structure, significantly reducing the overall weight of the insole while improving breathability. An adaptive wrapping area is located on the sidewalls and bottom perimeter of the elastic matrix, featuring a rotating square honeycomb lattice structure. When pressure is applied during walking, the sidewalls tighten inwards to conform to the foot, and the anti-slip texture formed by the lattice effectively prevents the insole from shifting within the shoe.

[0017] 2. The forefoot wedge structure of the elastic matrix in this invention is designed with the inner side higher than the outer side, with a height difference of 2mm to 3mm between the inner and outer sides and a wedge angle of 3° to 5°. The specific parameters can be adjusted according to the user's foot pronation degree. This structure can actively counteract the tendency of foot pronation to increase during pregnancy, guide the force point of the forefoot to spread evenly from the inner side to the entire foot when pushing off the ground, and reduce the excessive load on the inner side of the forefoot. Attached Figure Description

[0018] Figure 1This is a frontal view of the overall structure of the insole of the present invention; Figure 2 This is a front view schematic diagram of the Gyroid lattice structure of the arch region of the insole of the present invention; Figure 3 This is a front view schematic diagram of the Voronoi lattice structure in the heel region of the insole of the present invention; Figure 4 This is a front view schematic diagram of the Voronoi lattice structure in the forefoot region of the insole of the present invention; Figure 5 This is a top view schematic diagram of the rotating square honeycomb lattice in the side and bottom areas of the insole of the present invention; Figure 6 This is a schematic diagram of the forefoot wedge-shaped structure of the insole of the present invention; Figure 7 This is a schematic diagram of the heel cup structure of the insole of the present invention; Figure 8 This is a cross-sectional structural diagram of the insole of the present invention; Figure 9 This is a flowchart of the personalized customization method of the present invention.

[0019] In the diagram: 1. Arch support area (Gyroid lattice); 2. Shock absorption area (Voronoi lattice - heel); 3. Shock absorption area (Voronoi lattice - forefoot); 4. Lightweight filling area (hexagonal honeycomb lattice); 5. Adaptive wrapping area (rotating square honeycomb lattice); 6. Forefoot wedge structure; 7. Heel cup structure; 8. Flexible surface layer. Detailed Implementation

[0020] The technical solutions of this invention will now be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0021] Example: Please refer to the accompanying drawings of this invention. Figures 1 to 8 As shown, the present invention discloses a 3D-printed elastic support insole for pregnant women, comprising an integrally 3D-printed elastic matrix and a flexible surface layer composited on its top surface. The elastic matrix can be printed using foamed PEBA filaments via fused deposition modeling. The flexible surface layer is made of foamed memory foam fabric, which can be hot-pressed onto the top surface of the elastic matrix using an environmentally friendly hot-melt adhesive film. The foamed PEBA has the characteristics of low density, high elasticity, high energy return, and fatigue resistance, providing basic mechanical support and elastic recovery capabilities for the insole.

[0022] Furthermore, the elastic matrix is ​​divided into four lattice functional zones according to the functional requirements of the foot, and is also designed with a forefoot wedge structure and a heel cup structure to achieve a combination of lattice mechanical function and geometric orthopedic function. The specific structure is as follows: Arch support zone: Located on the inner side of the arch of the elastic matrix, it is configured with a Gyroid lattice structure with three-period minimal curved surfaces. This structure has a smooth and continuous topological morphology and a geometric feature with zero average curvature. Its lattice size and wall thickness can be adjusted according to the user's arch height gradient. When compressed, it can deform uniformly and store energy. After unloading, it rebounds quickly, accurately simulating the natural compression-rebound process of a healthy human arch. While providing anti-collapse support for collapsed arches, it retains the dynamic mobility of the arch and adapts to the biomechanical needs of the arch during pregnancy. Impact Absorption Zone: Distributed in the center of the heel and below the first and second metatarsal bones of the forefoot within the elastic matrix, this zone is the main area of ​​impact and pressure concentration on the sole of the foot during pregnancy. It is configured with a Voronoi lattice structure of a Thiessen polygon. This structure is a typical bending-dominated mechanical structure, where external loads are mainly borne through the bending deformation of the rods. It possesses a low effective elastic modulus and high energy absorption capacity, effectively absorbing the instantaneous impact force during the initial heel strike and alleviating the shear and bending forces during the forefoot push-off phase. Simultaneously, this structure employs a non-uniform gradient design, adjusting the distribution density of random seed points to increase cell wall thickness or decrease cell cavity size in the pressure peak region, effectively dispersing the peak pressure on the sole and avoiding adverse reactions caused by localized pressure concentration.

[0023] Lightweight filling area: Distributed in the non-primary pressure-bearing areas of the elastic matrix, excluding the arch support area and shock absorption area, it is configured with a conventional hexagonal honeycomb lattice structure. This structure can achieve high specific stiffness support with extremely low material usage, effectively reducing the overall weight of the elastic matrix. At the same time, the honeycomb pore structure also has good breathability and sweat absorption, improving wearing comfort.

[0024] Adaptive wrapping area: Distributed on the sidewalls and bottom periphery of the elastic matrix, configured as a rotating square honeycomb lattice structure. When compressed, this structure generates a negative Poisson's ratio effect, causing the insole sidewalls to automatically tighten towards the central axis of the foot, conforming to the foot contour that changes due to factors such as edema during pregnancy; at the same time, the edges and gaps of the lattice units form fine anti-slip textures, significantly enhancing the friction between the insole and the sole and side of the foot, fundamentally solving the problem of insole displacement during walking.

[0025] The arch support zone of the resilient matrix features a Gyroid lattice structure. Based on the characteristic of decreased arch height in pregnant women, the lattice period and rod diameter are adjusted to produce controllable elastic deformation under pressure and rapid rebound after unloading, providing dynamic lifting support for collapsed arches. The impact absorption zone, located in the center of the heel and below the first and second metatarsals in the forefoot, features a Voronoi lattice structure with gradient densification in the pressure peak area of ​​the first metatarsal. The cell wall thickness is increased compared to the surrounding areas, achieving pressure dispersion and efficiently absorbing landing impact and extension shear forces. The lightweight filling zone, located on the outer arch and midfoot, and other non-primary pressure-bearing areas, features a conventional hexagonal honeycomb lattice structure, significantly reducing the overall weight of the insole while improving breathability. The adaptive wrapping zone, located on the sidewalls and bottom perimeter of the elastic matrix, features a rotating square honeycomb lattice structure. When pressure is applied during walking, the sidewalls tighten inwards to fit the foot, and the anti-slip texture formed by the lattice effectively prevents the insole from shifting within the shoe.

[0026] The forefoot wedge structure of the elastic matrix is ​​designed with a higher inner side and a lower outer side, with a height difference of 2mm to 3mm between the inner and outer sides and a wedge angle of 3° to 5°. The specific parameters can be adjusted according to the user's foot pronation degree. This structure can actively counteract the tendency of foot pronation to increase during pregnancy and guide the force point of the forefoot to spread evenly from the inner side to the entire forefoot when pushing off the ground, reducing excessive load on the inner side of the forefoot.

[0027] The heel cup structure of the elastic matrix has a concave curved surface radius of curvature that matches the physiological curvature of the human calcaneus, which can tightly wrap the calcaneus, enhance the stability of the heel in the gait cycle, effectively alleviate the problem of heel eversion during pregnancy, and maintain the normal transmission of force lines in the lower limbs.

[0028] The forefoot area of ​​the elastic matrix features a wedge-shaped structure with a higher inner side and a lower outer side, with a height difference of 2mm to 3mm between the inner and outer sides and a wedge angle of 3° to 5°. This effectively counteracts excessive pronation of the pregnant woman's foot and guides the force point of the forefoot to spread to the entire foot. The heel area features a heel cup structure with a concave curved surface that adapts to the physiological curvature of the calcaneus, tightly wrapping the calcaneus, relieving heel eversion, and enhancing walking stability.

[0029] The flexible surface layer is made of memory foam fabric, which has slow rebound properties and can adaptively conform to the contour of a pregnant woman's foot, thereby homogenizing the pressure on the sole of the foot and eliminating local high pressure points. At the same time, it serves as a flexible buffer interface between the sole of the foot and the elastic matrix lattice structure, effectively buffering the minor discomfort caused by the lattice structure. In addition, the fabric is breathable and non-slip, further improving the wearing comfort and stability of the insole.

[0030] Meanwhile, this invention provides a personalized customization method for the above-mentioned 3D-printed elastic support insoles for pregnant women, comprising the following steps performed sequentially: S1: Foot 3D Geometric Data Acquisition: Using a high-precision 3D foot scanner, a 3D geometric model of the user's foot under load is acquired, and feature parameters such as arch height, foot length, foot width, foot circumference, and foot contour are accurately extracted to provide data support for the basic shape design of insoles.

[0031] S2: Foot pressure distribution data acquisition: Through the foot pressure analysis system, the foot pressure distribution data of users in static standing and dynamic walking states are collected to identify the pressure peak area, pressure center trajectory, pressure distribution difference between left and right feet and pressure transfer pattern in gait, providing a basis for the gradient design of insole lattice structure.

[0032] S3: Elastic matrix basic shape design: Based on the collected three-dimensional geometric model of the foot, the overall outline of the elastic matrix is ​​determined in 3D modeling software. At the same time, the basic shape of the forefoot wedge structure and heel cup structure that match the user's foot is designed to ensure the basic fit of the insole to the foot.

[0033] S4: Elastic matrix lattice structure parameter configuration: Based on the collected plantar pressure distribution data, the lattice type, relative density and gradient parameters of each functional zone of the elastic matrix are dynamically configured: a Gyroid lattice adapted to the arch height is generated in the arch support zone; a Voronoi lattice with density gradient variation is generated in the impact absorption zone, and the pressure peak zone is densified and thickened; a conventional hexagonal honeycomb lattice is generated in the lightweight filling zone; and a rotating square honeycomb lattice is generated in the adaptive wrapping zone.

[0034] S5: Synthesis of 3D Digital Model of Elastic Matrix: Boolean operation is performed on the basic morphological model of the elastic matrix and the lattice structure model of each functional zone to merge them into an integrated 3D digital model of the elastic matrix, ensuring smooth connection of each structure and matching of mechanical properties.

[0035] S6: 3D printing of elastic matrix: The three-dimensional digital model of the elastic matrix is ​​imported into the 3D printer. Foamed PEBA filament is used as the printing material. The appropriate printing layer thickness, nozzle temperature and other parameters are set. The fused deposition modeling process is used for integrated printing to obtain an elastic matrix without delamination or cracking. After printing, the excess support structure is cleaned up.

[0036] S7: Finished Insole Composite Molding: The foamed memory foam fabric is precisely cut according to the top contour of the elastic substrate. The flexible surface is tightly bonded to the top surface of the elastic substrate using an environmentally friendly adhesive or hot pressing process. After trimming and cleaning, the finished insole is obtained. The adhesive used is an odorless, low-irritant environmentally friendly material that meets the safety requirements of pregnant women.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A 3D-printed elastic support insole for pregnant women, characterized in that, It includes an integrated 3D printed elastic matrix and a flexible surface layer composited on the top surface of the elastic matrix. The interior is arranged with a heterogeneous lattice structure according to functional zones. The elastic matrix has a wedge-shaped structure with a higher inner and lower outer edge in the forefoot area and a heel cup structure adapted to the physiological curvature of the calcaneus in the heel area.

2. The elastic support insole for pregnant women according to claim 1, characterized in that: The lattice functional partitioning of the elastic matrix is ​​as follows: Arch support area: configured as a Gyroid lattice structure with three-period minimal curved surfaces; Shock absorption zone: distributed in the center of the heel and below the first and second metatarsal bones of the forefoot, configured as a Voronoi lattice structure of a Tyson polygon; Lightweight filling area: distributed in non-primary pressure-bearing areas other than the arch support area and impact absorption area, configured as a conventional hexagonal honeycomb lattice structure; Adaptive encapsulation region: distributed on the sidewalls and bottom periphery of the elastic matrix, configured as a rotating square honeycomb lattice structure.

3. The elastic support insole for pregnant women according to claim 2, characterized in that: The Gyroid lattice structure of the arch support area has its lattice size and wall thickness adjusted according to the user's arch height data. It can deform and store energy when compressed and rebound quickly after unloading, thus simulating the dynamic support function of a normal arch.

4. The elastic support insole for pregnant women according to claim 2, characterized in that: The Voronoi lattice structure of the impact absorption region is a non-uniform gradient design. By adjusting the distribution density of random seed points, the cell wall thickness is increased or the cell cavity size is reduced in the region corresponding to the pressure peak, thereby achieving foot pressure dispersion.

5. The elastic support insole for pregnant women according to claim 1, characterized in that: The height difference between the inner and outer sides of the forefoot wedge structure is 2mm to 3mm, and the wedge angle is 3° to 5°. It is used to counteract excessive pronation of the foot and guide the forefoot push-off force point to spread to the entire palm.

6. The elastic support insole for pregnant women according to claim 1, characterized in that: The concave surface radius of the heel cup structure is adapted to the physiological curvature of the calcaneus, which is used to stabilize the calcaneus and relieve heel eversion.

7. The elastic support insole for pregnant women according to claim 2, characterized in that: The rotating square honeycomb lattice structure of the adaptive wrapping region generates a negative Poisson's ratio effect when compressed, causing the sidewalls to tighten towards the central axis of the foot, and the edges and gaps of the lattice units form fine anti-slip textures.

8. The elastic support insole for pregnant women according to claim 1, characterized in that: The flexible surface layer is made of foamed memory foam fabric, which can adaptively conform to the contour of the foot, achieve secondary pressure equalization, and serve as a flexible buffer interface between the foot and the elastic matrix.

9. The elastic support insole for pregnant women according to claim 1, characterized in that: The elastic matrix is ​​made of foamed PEBA filament and printed using a fused deposition modeling process.

10. A 3D-printed elastic support insole for pregnant women and a personalized customization method thereof, the customization method being used to customize the elastic support insole for pregnant women as described in any one of claims 1-9, characterized in that, Includes the following steps: S1: Obtain a three-dimensional geometric model of the user's foot under weight-bearing conditions using a three-dimensional foot scanner, and extract characteristic parameters such as arch height, foot length, foot width, and foot circumference; S2: Collect plantar pressure distribution data of users in static standing and dynamic walking states through the plantar pressure analysis system, and identify the pressure peak area, pressure center trajectory and the difference in pressure distribution between the left and right feet; S3: Based on the three-dimensional geometric model of the foot in step one, determine the overall outline of the elastic matrix, the basic shape of the forefoot wedge structure, and the heel cup structure; S4: Based on the plantar pressure distribution data in step two, configure the lattice type, relative density and gradient parameters of each functional zone of the elastic matrix: generate a Gyroid lattice in the arch support zone, generate a Voronoi lattice with density gradient changes in the impact absorption zone, generate a conventional hexagonal honeycomb lattice in the lightweight filling zone, and generate a rotating square honeycomb lattice in the adaptive wrapping zone. S5: Perform Boolean operations on the basic morphological model from step three and the lattice structure model from step four to generate a three-dimensional digital model of the elastic matrix. S6: Import the three-dimensional digital model into a 3D printer and print it in one piece using foamed PEBA filament through fused deposition modeling process to obtain an elastic matrix; S7: After cutting the foamed memory foam fabric, it is laminated to the top surface of the elastic matrix using either an environmentally friendly adhesive or a hot-pressing process. After trimming and cleaning, the finished insole is obtained.

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