METHOD FOR PRODUCING AN ORTHOPEDIC FOOTBED ARRANGEMENT

Description

FIELD OF THE INVENTION

[0001] The present invention is generally directed to methods of making an orthotic footbed assembly, and more specifically directed to methods of making the orthotic footbed assembly by direct printing orthotic features onto a three-dimensional ("3-D") footbed, by indirect printing orthotic features and applying them onto to a 3-D footbed, and direct printing orthotic features onto a 2-D blank and then conducting a three-dimensional forming operation.

[0002] US 2015 / 0165690 A1 describes systems and methods for using a three-dimensional fabrication device, like a 3D printer, for automation and additive manufacturing techniques in manufacturing medical devices such as orthotics. GB 2 508 204 A relates to a method of manufacturing an orthosis using a 3D printer. EP 3 001 925 A1 relates to an article of footwear as well as a method of making such an article of footwear. WO 2016 / 075429 A1 relates to a method of making an orthotic.BRIEF SUMMARY

[0003] In at least one aspect of the present invention, a method of making an orthotic footbed assembly includes the steps of (1) scanning a customer's foot; (2) based on the scan, selecting a three-dimensional footbed that most closely approximates a size and configuration of the customer's foot; (3) based on the scan, determining at least one orthotic feature for the three-dimensional footbed; and (4) directly printing the at least one orthotic feature onto the three-dimensional footbed.

[0004] In at least another aspect of the present invention, a method of making an orthotic footbed assembly includes the steps of (1) scanning a customer's foot; (2) based on the scan, selecting a three-dimensional footbed that most closely approximates a size and configuration of the customer's foot; (3) based on the scan, determining at least one orthotic feature to be printed onto a substrate; (4) directly printing the at least one orthotic feature onto the substrate; and (5) securing the at least one orthotic feature onto the three-dimensional footbed.

[0005] In yet another aspect, an orthotic footbed assembly includes a three-dimensional footbed that closely approximates a size and configuration of a particular foot and at least one orthotic feature additively coupled to the three-dimensional footbed.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings: FIGURE 1A is a schematic, plan view of an orthotic footbed assembly; FIGURE 1B is a cross-sectional view of the orthotic footbed assembly of FIGURE 1A having an orthotic feature applied to a 2-D blank; FIGURE 1C is a cross-sectional view of the orthotic footbed assembly of FIGURE 1A having an orthotic feature applied to a 3-D footbed; FIGURE 2 is a method for making an orthotic footbed assembly by direct printing onto a 3-D footbed according to an embodiment of the present invention; FIGURE 3 is a method for making an orthotic footbed assembly by indirect printing onto a substrate according to an embodiment of the present invention; and FIGURE 4 is a method for making an orthotic footbed assembly by direct printing onto a 2-D blank, not forming part of the claimed invention. DETAILED DESCRIPTION

[0007] In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments of the invention. However, one skilled in the art will understand that the invention may be practiced without these details. In other instances, well-known structures associated with footwear, insoles, midsoles, non-removable soles, footbeds, orthotics, combinations thereof, and methods of making the same, have not necessarily been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments of the invention.

[0008] The invention is defined by the appended independent claims 1 and 10. Additional embodiments are defined in the dependent claims. These methods, various combinations of these methods, and additions thereto are described in more detail below. For purposes of the description, claims, other text and drawings herein, a footbed should be broadly interpreted as any platform, support or other structure that runs under the bottom of a person's foot. The footbed may take the form of, but is not limited to, an insole, a midsole, a sandal sole, or an inner sole (sometimes referred to as an innersole).

[0009] Printing an entire footbed assembly can be quite time-consuming. Further, much of the footbed is fairly common from one person to another with respect to foot size and general foot shape. Thus, the present invention provides a process to produce a custom footbed assembly that, according to at least one embodiment, starts with a 3-D footbed that closely approximates the foot of person. 3-D orthotic features are then printed onto or secured onto the 3-D footbed to account for foot specifics of a particular customer that were not adequately addressed by the stock 3-D footbed.

[0010] FIGURE 1A shows an orthotic footbed assembly 100 having a footbed 102, at least one heel orthotic feature 104, at least one medial or lateral orthotic feature 106, and at least one forward orthotic feature 108. FIGURE 1B shows the heel orthotic feature 104 applied to a 2-D flat or planar blank 102a while FIGURE 1C shows the heel orthotic feature 104 applied to a 3-D footbed 102b.

[0011] The footbed 102 may take the form of a standard, off-the-shelf footbed base structure or some other type of footwear item (e.g., shoes, sandals, flip-flops, etc.). It may alternatively be a generalized footbed base or midsole created to fit a large cross section of people of a certain foot size, gender, and race. Such a footbed or midsole could be specially created to include regions designated to receive added orthotic features, either to be printed directly thereon or secured thereon with adhesive or other methods. Thus, the generalized base or black may even have recesses therein to receive the orthotic features.

[0012] The footbed 102 may be 3-D or 2-D when obtained. In one embodiment, the footbed takes the form of a flat blank that is stamped, pressed, or otherwise formed into a curved configuration. The term "orthotic feature" may take the form of a raised or a depressed region printed directly onto the footbed or made separately and subsequently attached to the footbed. For purposes of the description herein, the term "orthotic" should be broadly interpreted as any element, component, device or support, especially for the foot, used to relieve or correct an orthopedic problem, provide a therapeutic benefit, assist with walking or wearing comfort of a footwear item, provide some other type of benefit or improvement for a wearer of the footbed assembly, or any combination thereof. The direct application of the orthotic feature onto the footbed may be accomplished by techniques such as, but not limited to, stereolithography, 3-D printing, additive printing or additive manufacturing, and other techniques where material may be selectively added to a footbed, substrate, or blank in thin layers.

[0013] FIGURE 2 shows a method 200 for making a customized orthotic footbed assembly. At Step 202, the customer's foot is scanned to determine a variety of aspects and information about the customer's foot. For purposes of this description, the term "scan" should be broadly interpreted to include any physical, analog or digital technique that may be used to obtain information about the foot. In at least some embodiments, scanning the customer's foot includes performing a plantar digital foot scanning procedure to capture a volumetric foot model, and in particular capture the crucial posterior calcaneus of the foot. In at least some other embodiments, scanning the customer's foot includes performing a diagnostic ultrasound that produces images of internal foot structures through the use of highfrequency sound waves, whose echoes are used to create moving and still images of the muscles, tendons, ligaments, joints and other soft tissue in the foot and ankle. In still other embodiments, scanning the customer's foot includes performing a digital orthotic scanning that generates a 3-D map of the foot, which effectively images the biomechanical structure and at least some foot abnormalities. In still yet other embodiments, scanning the customer's foot includes using optical (e.g., laser) scanners that capture a contour and position of the posterior aspect of the heel as well as other aspects or portions of the foot. Imaging the posterior aspect of the heel may help in evaluating the forefoot-to-rearfoot relationship, which is a parameter that may be used in making a customized orthotic footbed assembly. Additionally or alternatively, any of the aforementioned scanning techniques may be used in conjunction with plaster casts, foam box impressions and other physical approximation techniques.

[0014] At Step 204, at least one 3-D footbed is selected or otherwise obtained. The 3-D footbed may include various curves and contours that be selected based on the scan of the foot. Alternatively, the 3-D footbed may be unrelated to the scan and merely have a general shape that corresponds to a foot. The 3-D footbed may be selected from a variety of footbeds ranging in size, width, material, density, and other parameters. Additionally or alternatively, the 3-D footbed may be special ordered or made for a certain type of foot.

[0015] At Step 206 and based on the scan, at least one orthotic feature is determined for the 3-D footbed. At Step 208, at least one orthotic feature is directly printed onto the 3-D footbed to form a 3-D orthotic footbed assembly. At Step 210, an overlay material may be optionally applied onto the 3-D orthotic footbed assembly. In at least one embodiment, the overlay material may be a soft overlay material such as, but not limited to, a foam or a dense foam. It may also be an overlying fabric material as an overlay or on top of the foam to form an overlay as a combination of foam and fabric.

[0016] FIGURE 3 shows a method 300 for making a 3-D customized orthotic footbed assembly that starts with a 3-D footbed. Step 302 is the same as Step 202 (FIGURE 2) in which the customer's foot is scanned to determine a variety of aspects and information about the customer's foot.

[0017] At Step 304, at least one 3-D footbed is selected or otherwise obtained. The 3-D footbed may generally include various curves and contours that are not selected from the scan of the foot. Stated otherwise, the 3-D footbed is unrelated to the scan and merely includes a general shape that corresponds to a foot. The 3-D footbed may be selected from a variety of footbeds ranging in size, width, material, density and other parameters. Additionally or alternatively, the 3-D footbed may be special ordered or made for a certain type of foot.

[0018] At Step 306, at least one orthotic feature is directly printed onto a substrate such as, but not limited to, an adhesive substrate. Based on the scan of the foot, one or more orthotic features are printed onto the adhesive substrate. At Step 308 and according to the present embodiment, the orthotic features are adhesively coupled to or adhesively attached to the 3-D blank to create a low-cost, 3-D customized orthotic footbed assembly, which may be quickly produced. At Step 310, an overlay material may be optionally applied onto the 3-D orthotic footbed assembly.

[0019] FIGURE 4 shows a method 400 for making a 3-D customized orthotic footbed assembly that starts with a 2-D blank or footbed. Step 402 is the same as Step 202 (FIGURE 2) in which the customer's foot is scanned to determine a variety of aspects and information about the customer's foot.

[0020] At Step 404, at least one 2-D blank or blank is obtained. The 2-D blank is generally flat or planar, but may include various curves and contours along a length and width of the 2-D structure. In at least some embodiments, the 2-D blank is unrelated to the scan (e.g., standard) and merely includes a general shape that corresponds to a foot. The 2-D blank may be selected from a variety of blanks ranging in size, width, material, density, and other parameters. Additionally or alternatively, the 2-D blank may be special ordered or made for a certain type of foot.

[0021] At Step 406, at least one orthotic feature is directly printed onto the 2-D blank based on the scan of the foot to for a 2-D orthotic footbed. At Step 408 and according to the present embodiment, the 2-D orthotic footbed is formed or shaped into a 3-D customized orthotic footbed assembly. At Step 410, an overlay material may be optionally applied onto the 3-D orthotic footbed assembly.

[0022] While preferred embodiments of the invention have been illustrated and described, other advantages will also be apparent to those of skill in the art with respect to any of the above-described embodiments whether viewed individually or in some combination thereof. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.

Claims

1. A method (200) of making an orthotic footbed (100) assembly, the method (200) comprising: scanning a customer's foot (202); based on the scan, selecting a three-dimensional footbed (102) that most closely approximates a size and configuration of the customer's foot (204); based on the scan, determining at least one orthotic feature (104, 106, 108) for the three-dimensional footbed (206); and directly printing the at least one orthotic feature (104, 106, 108) onto the three-dimensional footbed (102) (208).

2. The method (200) of claim 1, wherein scanning (202) includes digital, optical imaging.

3. The method (200) of claim 1, wherein scanning (202) includes ultrasound imaging.

4. The method (200) of claim 1, wherein selecting the three-dimensional footbed (102) (204) includes selecting the three-dimensional footbed (102) from an inventory of three-dimensional footbeds.

5. The method (200) of claim 1, wherein selecting the three-dimensional footbed (102) (204) includes making the three-dimensional footbed (102).

6. The method (200) of claim 1, wherein determining at least one orthotic feature (104, 106, 108) (206) includes determining a location where additional material is to be added to the three-dimensional footbed (102).

7. The method (200) of claim 1, wherein directly printing (208) includes three-dimensional printing.

8. The method (200) of claim 1, wherein directly printing (208) includes additive manufacturing.

9. The method (200) of claim 1, further comprising applying an overlay material onto the orthotic footbed assembly (210).

10. A method (300) of making an orthotic footbed assembly, the method comprising: scanning a customer's foot (302); based on the scan, selecting a three-dimensional footbed (102) that most closely approximates a size and configuration of the customer's foot (304); based on the scan, determining at least one orthotic feature (104, 106, 108) to be printed a substrate; directly printing the at least one orthotic feature (104, 106, 108) onto the substrate (306); and securing the at least one orthotic feature (104, 106, 108) onto the three-dimensional footbed (102) (308).

11. The method (300) of claim 10, wherein scanning (302) includes ultrasound imaging.

12. The method (300) of claim 10, wherein determining at least one orthotic feature (104, 106, 108) includes determining a location where additional material is to be added to the three-dimensional footbed (102).

13. The method (300) of claim 10, wherein directly printing (306) includes three-dimensional printing.

14. The method (300) of claim 10, further comprising applying an overlay material onto the orthotic footbed assembly (100) (310).

15. The method (300) of claim 10, wherein the substrate is an adhesive substrate, and securing the at least one orthotic feature (104, 106, 108) onto the three-dimensional footbed (308) includes adhesively coupling or adhesively attaching the at least one orthotic feature (104, 106, 108) printed on the substrate to the three-dimensional footbed (102) (306).