Method and assembly for producing individualized insoles

Abstract

The invention relates to a method and an assembly for producing an insole (13) which is individualized for a specific person and for a specific shoe (12), having the following steps and components: - acquiring a first digital data set (1) by 3D scanning the foot (14) or at least the underside of the foot of the person, - acquiring a second digital data set (2) by 3D scanning at least part of the existing standard insole (15) of the shoe (12), - creating a digital 3D model (11) of the individualized insole (13) using the first data set (1) and the second data set (2), and - additively manufacturing the insole on the basis of the 3D model (11).

Description

[0001] Method and arrangement for producing customized insoles

[0002] The invention relates to a method, an arrangement and an article according to the features of the independent patent claims.

[0003] Individual steps of a method and individual components of an arrangement for producing an object adapted to the body of a living being, such as an orthosis, a prosthesis, or protective equipment, are described. Individual steps of methods and individual components of arrangements for creating a digital 3D model of the object or a part thereof, as well as individual steps of methods and individual components of arrangements for manufacturing the object or a part thereof, are also described.

[0004] Also described are overall processes and entire arrangements for producing a customized article. The process is preferably fully automated. The disclosed customized articles can be stand-alone components, such as parts of protective equipment, external orthoses, or the like, or inserts or components for other articles, such as customized insoles for shoes or customized inserts for helmet shells. The shoes can, for example, be sturdy sports shoes such as ski boots, hiking boots, or ice skates. Alternatively, the shoes can be lightweight sports shoes such as running shoes.

[0005] The item can be adapted to any person or living being. Alternatively, the item can also be adapted to any other object. For example, the item can be customized protection for products, devices, or instruments. The item can be, for example, an insert for a bag or case, e.g., a customized insert for a suitcase, a tool case, an instrument case, a transport box, or another container.

[0006] Methods and devices for producing objects adapted to the body shape of a living being have been known and published for some time.

[0007] While in the past, impressions were usually taken from certain areas of the body, which subsequently led to an object adapted to the body in one or more modeling steps, the accessibility of modern technologies has made new procedures and arrangements possible.

[0008] In particular, new technologies such as 3D scanning devices and 3D printers offer good opportunities for the efficient, simple and precise production of individualized objects while avoiding unnecessary waste.

[0009] Conventional methods and arrangements for creating a customized object are usually very complex, as they require expensive equipment and, in some cases, time-consuming modeling work. The object of the invention is to overcome the disadvantages of the prior art and create an efficient way of creating a customized object.

[0010] The problem is solved in particular by the features of the independent patent claims.

[0011] Disclosed is a method for producing an insole customized for a specific person and for a specific shoe, comprising the following steps:

[0012] - Capturing a digital first data set by 3D scanning the foot or at least the bottom of the person's foot,

[0013] - Capturing a digital second data set by 3D scanning at least part of the existing standard insole of the shoe,

[0014] - Creating a digital 3D model of the customized insole using the first data set and the second data set,

[0015] - additive manufacturing of the insole based on the 3D model.

[0016] Where appropriate, the first data set and the second data set are acquired by the same 3D scanning device.

[0017] If appropriate, it is provided that the first data set and the second data set are captured by the 3D scanning device of a mobile device, in particular a smartphone.

[0018] If necessary, the first data set is acquired by 3D scanning the bottom of the foot and additionally by 3D scanning other areas of the foot, such as in particular the top of the foot, the heel area and / or the ankle area.

[0019] If necessary, the existing standard insole of the shoe is removed from the shoe and 3D scanned to capture the second data set. If necessary, the outline of the existing standard insole of the shoe is 3D scanned to capture the second data set.

[0020] If necessary, the existing standard insole of the shoe will be replaced by the customized insole.

[0021] If necessary, it is provided that a third data set is included in the creation of the 3D model, wherein the third data set is a data set of a reference model of an insole, which is adapted to the circumstances of the person and the shoe by including the first data set and the second data set.

[0022] Where appropriate, the first data set is intended to essentially determine the shape of the 3D model on the upper side of the insole facing the person's foot.

[0023] If necessary, the shape of the top of the insole can be orthopedically corrected or adjusted.

[0024] Where appropriate, the second data set is intended to essentially determine the shape of the 3D model on the surface facing the shoe and thus the outline of the insole.

[0025] If necessary, it is envisaged that a fourth data set will be included in the creation of the 3D model, whereby the fourth data set determines the structure and in particular the lattice structure of the 3D model of the insole and thus physical parameters such as density and stiffness of the insole.

[0026] Where appropriate, the first data set and the second data set are to be sent to a central server via the Internet.

[0027] If appropriate, the 3D model of the insole is created by or on the central server. If appropriate, the 3D model of the insole is created by sending the first data set and the second data set to the server and, if appropriate, receiving the 3D model of the insole. Alternatively, the 3D model is sent from the server to an additive manufacturing device, and the finished insole is sent back to the person.

[0028] Where appropriate, the filling of the insole may be lattice-shaped and, in particular, comprise interconnected cavities or channels.

[0029] If appropriate, it is provided that the insole is formed at least partially, preferably entirely, from a flexible 3D-printable material, in particular from TPU.

[0030] If necessary, the additive manufacturing of the insole is planned to be carried out by a 3D printer that uses the fused deposition modeling (FDM) process.

[0031] If necessary, it is provided that the air in the build chamber of the 3D printer is cooled by active air conditioning using an air conditioning unit with a build chamber fan to a build chamber temperature of less than or equal to 20°C, preferably less than or equal to 15°C.

[0032] If necessary, it is provided that the air in the build chamber of the 3D printer is conditioned by active air conditioning using an air conditioning unit with a build chamber fan to a relative humidity of less than or equal to 25%, preferably less than or equal to 20%.

[0033] If appropriate, a ring-shaped swirl nozzle surrounding the 3D printer's print head emits a twisted air stream along the print material's output direction. If appropriate, the print material is cooled before and / or during processing in the 3D printer, particularly by the air conditioning unit.

[0034] If necessary, it is provided that the printing material is cooled immediately before or upon entry into the print head so that the printing material, in particular the filament, has a lower temperature in the area of ​​its outer surface or surface than in the core area.

[0035] Where appropriate, it is intended that the additive manufacturing of the insole takes place in a time of less than or equal to 20 minutes.

[0036] Disclosed is an arrangement for producing an insole customized for a specific person and for a specific shoe, comprising:

[0037] - a 3D scanning device for capturing a digital first data set by 3D scanning the bottom of the person's foot and for capturing a digital second data set by 3D scanning the existing standard insole of the shoe,

[0038] - a data processing arrangement, in particular a server, for creating a digital 3D model of the individualised insole, including the first data set and the second data set,

[0039] - and a 3D printer for additive manufacturing of the insole based on the 3D model.

[0040] An insole is disclosed, manufactured according to the described method and / or on a described arrangement.

[0041] Disclosed is a method and a system for producing an article individualized for a specific object, comprising the following steps or components:

[0042] - capturing a digital first data set by 3D scanning at least a part of the object to which the article is to be adapted,

[0043] - if necessary, capturing a second digital data set by 3D scanning at least part of an object to be replaced or part of the object, - creating a digital 3D model of the individualised object, including the first data set and, if necessary, the second data set,

[0044] - additive manufacturing of the object based on the 3D model.

[0045] Disclosed is a method and a system for producing an article individualized for a specific object, comprising the following steps or components:

[0046] - capturing a digital first data set by 3D scanning at least a part of the object to which the article is to be adapted,

[0047] - if necessary, capturing a digital second data set by 3D scanning at least part of an object to be replaced or part of the object,

[0048] - sending the first data set and, if recorded, the second data set to a server and obtaining a digital 3D model of the individualised object, including the first data set and, if recorded, the second data set,

[0049] - additive manufacturing of the object based on the 3D model.

[0050] A method for producing an article individualized for a living being and for a specific object is disclosed, comprising the following steps or components:

[0051] - capturing a digital first data set by 3D scanning at least part of the living being,

[0052] - if necessary, capturing a digital second data set by 3D scanning at least part of an object to be replaced or part of the object,

[0053] - Creating a digital 3D model of the individualised object, including the first data set and, if applicable, the second data set,

[0054] - additive manufacturing of the object based on the 3D model.

[0055] If appropriate, the 3D model of the customized item is created by sending the first data set and, if applicable, the second data set to a server. The 3D model is calculated on the server and can then be received back from the server. Alternatively, the 3D model is sent from the server to an additive manufacturing device, and the person then receives the finished customized item.

[0056] It is preferably provided that the first data set essentially determines the shape of the 3D model on the side of the object facing the living being during intended use, wherein the shape on the side of the object is orthopedically corrected or adapted if necessary.

[0057] It is preferably provided that the second data set essentially determines the shape of the 3D model on the surface facing the object and thus, if applicable, the outline of the object.

[0058] The data sets can be in any suitable file format. Preferably, the first data set and / or the second data set are each a three-dimensional surface model or a three-dimensional volume model, such as an STL file, a mesh file, or a polymesh file.

[0059] The first digital data set is preferably a digital 3D model, in particular a three-dimensional surface model of the scanned body part, such as a scanned foot. This can involve scanning only one side of the body part or an entire part of the body or extremity.

[0060] The 3D scan can be performed by trained personnel or by an untrained user. The process can be fully standardized and / or automated.

[0061] Preferably, a second digital data set is captured or created by 3D scanning. This is particularly advantageous when the object to be manufactured is to be adapted to another object, and especially when the manufactured object is part of a composite object. According to one example, an existing object can be replaced by a customized object. For example, a standard insole of a shoe can be replaced by a customized insole.

[0062] According to another example, an insert shell of a helmet can be replaced by a customized insert shell.

[0063] To create the digital second data set, either the item to be replaced, for example the standard insole or the

[0064] The standard helmet inner shell can be scanned. Alternatively or additionally, the object to which the customized item is to be connected can also be scanned. For example, the interior of the shoe or the interior of the helmet can be scanned. For this purpose, it is advantageous, or even necessary, to remove the item to be replaced before scanning.

[0065] The second data set, like the first, can be a digital surface model or a digital volume model. It can be captured using conventional 3D scanners.

[0066] For example, a camera module or the facial recognition module of a mobile device, such as a mobile phone, can be used for this purpose. In particular, mobile devices have 3D scanning devices, such as a so-called TrueDepth camera or a LiDAR scanner.

[0067] If necessary, a fully volumetric scan can be performed to create the first dataset and, if necessary, the second dataset, to capture not only the surface but also the volume. This can, for example, provide improved size determination. Especially in conjunction with the scan for the second dataset, this can improve classification.

[0068] To produce the customized object, a 3D model of the object is created. This 3D model is created using the first data set. Specifically, the manufactured object should be adapted to a body or another object. If the object interacts with another object, the second data set is also incorporated into the creation of the 3D model of the customized object. For example, the first data set is used to adjust the side of an insole that rests on the foot. Additionally, the second data set can be used to adjust the outline, i.e., the size and shape, of the insole.

[0069] This makes it possible to replace any object with a customized object without having to access detailed information about the object to be replaced. For example, there are a large number of different ski boots, each requiring different inner contours and thus different insole shapes. To replace the insole of a ski boot with a customized insole, a database would have to store information about which ski boot model has which insole contour. According to an example disclosed here, this can be omitted if, in addition to the foot, the insole to be replaced is also scanned.

[0070] The digital 3D model is created using the first data set and, preferably, the second data set as well. The outer surface does not have to exactly match the geometry captured by 3D scanning. For example, the surface of an insole does not have to exactly match the captured surface of the foot, but can be partially or completely adapted. The adaptation can, for example, be based on orthopedic considerations. The same applies to other types of

[0071] Items such as other orthoses, prostheses or protective equipment.

[0072] The customized object is preferably manufactured using an additive manufacturing process, in particular 3D printing. The 3D printer or additive manufacturing process can, for example, take place at the same location as the scanning of the first data set. Alternatively, additive manufacturing can also take place at a different location. According to a first example, the 3D scanning device and the device for additive manufacturing are located at the same location, for example in a sales room or a doctor's office. In this case, the surface of the body part to which the object is to be adapted is first scanned. If necessary, a second data set is also created by scanning an object to be replaced. In a further step, the digital 3D model is created and produced using additive manufacturing at the same location. This allows the person to try on the object immediately and take it home.It is advantageous if the duration of additive manufacturing is kept short and, in particular, less than or equal to 20 minutes.

[0073] According to another example, the 3D scanning device and the additive manufacturing device are located at different locations. For example, a person can scan the surface of the body part to which the object is to be adapted anywhere, such as at home. This 3D scanning can be carried out using a mobile device, such as a mobile phone. If necessary, the person can also create a second data set by scanning the object to be replaced or the object into which the adapted object is to be inserted. For example, the person can remove the existing standard insole from the shoe and scan this as well with the mobile phone. Alternatively or additionally, they can scan the interior of the shoe. In a further step, the 3D model is created using the first and, if necessary, also the second data set.This 3D model can then be additively manufactured. Additive manufacturing can take place at another location, such as a central production site. From this location, the customized item can be shipped, for example, in the form of a parcel, to any address.

[0074] When creating the 3D model, a third data set can be included, which can serve as a reference model of the customized object. For example, the third data set could be a reference insole, a reference orthosis, or another object. The basic shape of this reference model can then be adjusted and customized depending on the first data set and, if necessary, the second data set as well.

[0075] If necessary, a fourth data set can be included when creating the 3D model, whereby the fourth data set contains parameters of the structure of the 3D model or of the object to be created. For example, the fourth data set can relate to parameters of the density, stiffness, lattice structure or other parameters. For example, the fourth data set can relate to parameters such as how dense the lattice structure of the object to be created is. For example, the lattice structure for an insole of a running shoe can be less dense than the lattice structure for an ice skate. For example, for an orthosis, the lattice structure can be denser in one place than in another, meaning that the orthosis can have different densities or different stiffnesses in different areas. For example, the selection or creation of the fourth data set can take place by querying parameters.For example, the user can define the type, properties, and / or effects of the object via a user interface. For example, with an insole, the user can select the type of shoe, such as whether it's a running shoe or a ski boot. For example, the user can choose whether the customized object should be softer or harder.

[0076] Preferably, the 3D model of the customized object is created by or on a central server. This central server can be connected, for example, via the Internet to the 3D scanning device and, if applicable, to the additive manufacturing device. For example, a server is provided with which data can be exchanged via the Internet. The first data set, which is recorded, for example, by the user via 3D scanning, can be sent via the Internet to the central server, where the 3D model is then created or calculated. This 3D model, in particular control data for the additive manufacturing device, can then be sent to the additive manufacturing device. The customized object can have a selectable, suitable structure or a selectable, suitable filling that is formed during additive manufacturing.For insoles, for example, it is advantageous if the insole is designed in a grid-like and breathable manner. For other applications, such as orthotics, it can be advantageous if the base body is at least partially 100% filled, thus providing greater rigidity. If the filling extends to the outside, a denser filling can create a smoother outer surface, which then results in improved pressure distribution when applied to the body.

[0077] Preferably, the device for additive manufacturing is a 3D printer, and in particular a 3D printer that operates according to the FDM process.

[0078] It can be advantageous to keep the printing speed high and thus the production time short. For example, it can be advantageous if an item can be printed in less than half an hour. This time is particularly advantageous if a customer can wait in a store for the item to be manufactured on-site.

[0079] To optimize the FDM printing process, one or more of the following improvements can be made:

[0080] If necessary, the 3D printer's build chamber can be air-conditioned. In particular, the build chamber temperature and / or the temperature for conditioning the print material should be less than or equal to 25°C, preferably less than or equal to 20°C, and most preferably less than or equal to 15°C. Air conditioning can increase printing speed. Cooling the build chamber allows the molten print material to solidify more quickly. Care should be taken to avoid water condensation.

[0081] If necessary, multiple chambers are provided. For example, the printing material can be stored in a climate-controlled area or in a climate-controlled chamber of the 3D printer. Climate control is preferably provided by an air conditioning unit. This air conditioning unit can be part of the additive manufacturing device.

[0082] Cooling can influence the behavior of the filament in the extruder. Inertia, latency, and elasticity can be reduced because the filament's plastic becomes stiffer and harder. It may also increase heat dissipation at the nozzle, enabling higher speeds.

[0083] If necessary, a build space fan can be provided to move and, in particular, circulate the air within the build space. The build space fan is preferably provided in addition to a fan of the 3D printer's nozzle head. The build space fan is, for example, the fan of an air conditioning module and introduces a conditioned air flow into the build space.

[0084] Preferably, the relative humidity in the build chamber is maintained at or below 25% or below 20% through active air conditioning. Drying can prevent condensation, for example, in a cooled build chamber. This air conditioning can be achieved by one or the same air conditioning unit.

[0085] If necessary, a print head nozzle is provided in the area of ​​the print head, which directs an air stream directly onto the printing point or onto the output printing material. This nozzle can preferably be designed as a swirl nozzle, which delivers a twisted air stream along the output direction of the printing material.

[0086] If necessary, the printing material itself can be cooled before and / or during processing in the 3D printer. For example, the printing material can be provided or stored in an air-conditioned area or in an air-conditioned chamber of the 3D printer.

[0087] Alternatively or additionally, the printing material can be cooled immediately before entering the print head, particularly in its extruder or feed unit, so that the printing material, for example the filament, is cooled on its outer surface, but the core has a higher temperature. This can make the surface of the filament relatively cool and therefore hard, allowing it to be fed easily. A temperature below room temperature, for example, can be assumed to be cool. However, the core can be warmer than the surface, allowing an efficient melting process. Melting takes place in the melting area of ​​the print head. A temperature gradient from the core to the outer surface can have a positive effect, especially with thicker filaments.

[0088] The filament can be cooled during feeding. For example, the filament is fed to the print head or extruder in a feed hose. This hose can have a certain oversize so that a conditioned gas stream can be conveyed alongside the filament. The conditioned gas stream is preferably cooled and may also have a reduced relative humidity. The conditioned gas stream can, for example, operate according to the countercurrent principle and flow against the direction of the filament feed. Alternatively, the conditioned gas stream can flow in the same direction as the filament feed. The conditioned gas stream can also be used, for example, to solidify the molten printing material by cooling. For this purpose, the gas stream or a portion of the gas stream can exit in the area of ​​the print head. The gas stream can be combined with a print head blower or replace the print head blower.The conditioned gas is preferably air. Preferably, all areas are air-conditioned by a single air-conditioning unit, which can be part of the additive manufacturing facility, and in particular the 3D printer.

[0089] Cooling of the printing material can be achieved through surface contact, if necessary. For example, through a cooling element such as a Peltier element, which is located at the inlet of the print head or its extruder. A suitable geometry can guide and simultaneously cool the printing material.

[0090] In addition, a cooling element such as a Peltier element can be used to cool the entire extruder and the conveying elements.

[0091] Alternatively or additionally, at least one conveying element for conveying the printing material can be cooled. For example, a gear for conveying the printing material can be cooled, which cools the outside of the printing material during conveyance.

[0092] The printing material can be, for example, an elastic thermoplastic, TPU, or TPE, e.g., the product Pedcad Speed. The printing material is preferably a filament. The printing material preferably has a Shore hardness of less than A95. The printing material preferably has a high elongation or deformation rate. The printing material preferably has good recovery properties.

[0093] A preferred filament has a thickness of greater than 0.5 mm, preferably about 0.8 mm.

[0094] For example, the printing speed can be more than 120 mm / s.

[0095] The output quantity of the printing material can, for example, be more than 45 mm 3 / s, preferably more than 70 mm 3 / s, particularly preferably more than 80 mm 3 / s.

[0096] The filling of the customized object can affect its physical properties.

[0097] For example, a 30% filling can be selected.

[0098] The filling can be linear, for example 3-axis (120°) or 4-axis (90°). In this case, parallel paths are printed layer by layer, whereby the paths run at a certain angle, e.g. 120°, to the paths of the adjacent layer, depending on the design. The density of the nodes, i.e. points at which a path of one layer is in contact with a path of an adjacent layer, influences the stiffness of the printed object. Preferably, the nodes of two layers do not lie directly at nodes of the two adjacent layers. The paths of a newly applied layer preferably run along the layer plane at a distance from the nodes, i.e. between the nodes, of the two layers onto which the new layer is applied. New paths therefore preferably run on bridge sections of the underlying layer lying between nodes.

[0099] In principle, however, other suitable fillings are also conceivable.

[0100] In the following, steps of the method and components of the arrangement are further described.

[0101] Fig. 1 shows a schematic representation of steps of the method and components of the arrangement.

[0102] Fig. 2a shows an oblique view of a possible vortex nozzle. Fig. 2b shows a schematic sectional view of a portion of the vortex nozzle from Figure 2a.

[0103] Unless otherwise stated, the reference numerals correspond to the following components: first data set 1 , second data set 2, third data set 3, fourth data set 4, living being 5, object 6, object to be replaced 7, individualized object 8, 3D scanning device 9, additive manufacturing device 10, 3D model 11 , shoe 12, insole 13, foot 14, standard insole 15, outline 16, server 17, build space 18, build space blower 19, swirl nozzle 20, print material 21 , print head 22, feed hose 23, air conditioning unit 24, user interface 25, nozzle ring 26, outlet opening 27, nozzle channel 28.

[0104] Fig. 1 shows a schematic flow of a possible method based on an exemplary embodiment. In this exemplary embodiment, a customized insole 13 is formed. This insole is adapted to a person's foot 14.

[0105] In principle, however, the described method and also the described arrangement can be used for any objects 8 that are adapted to any objects 6. For example, the object 8 can be an orthosis, a prosthesis, or protective equipment. In particular, the object 8 can be a stand-alone object such as an external orthosis, for example a rigid knee orthosis or a customized helmet. Alternatively, however, the object 8 can also be a customized insert or attachment that is connected to a standard object 6. For example, the object 6 can be a standard helmet shell into which the customized object 8 is inserted in order to adapt it to a person's head. In the present case, the object 6 is a shoe 12 and the customized object is an insole 13. The adaptation of the object 8 can be made to any person or any living being 5.The item 8 can alternatively be adapted to any other object and can, for example, also serve as adapted protection for technical devices, musical instruments, inserts for tool cases or other boxes.

[0106] For simplicity, the method and arrangement are explained using this illustrative example. The method and arrangement are also described together.

[0107] In the present example, a first data set 1 is created. For this purpose, a 3D scan of part of the person's foot 14 is made. If an insole 13 is being created, it may be sufficient to scan the underside of the foot 14. However, if necessary, the entire foot 14 or, for other applications, other areas of the living being 5 or the person can be scanned. According to this example, a mobile device, such as a smartphone, can be used as the 3D scanning device 9. Modern smartphones usually include various cameras that can be used as 3D scanning devices 9. Particularly suitable for this purpose are those camera devices used for facial recognition to unlock the mobile phone.

[0108] Software can be used on the mobile device that enables the creation of the first data set 1. In particular, the 3D scanning device 9 can comprise a user interface 25 that, if necessary, provides the user with instructions on how to perform the scan or which steps to perform.

[0109] In the example, a second data set 2 is created. In this case, the second data set 2 is used to determine the shape of the customized object 8 so that it fits with the object 6. In this example, the object 8 is intended to replace another object 7. Thus, the standard insole 15 of a shoe 12 is replaced by a customized insole 13.

[0110] In order to determine the size and in particular the outline 16 of the insole 13, the standard insole 15 is removed from the shoe 12 and, in a further step, the standard insole 15 can be scanned with a 3D scanning device 9. This is preferably the same 3D scanning device 9 as used in the scan to create the data set 1, i.e., the 3D scanning device 9 of a mobile device, such as, in particular, a smartphone. As an alternative to the example described here, instead of a 3D scan of the item 7 to be replaced, the object 6 can also be scanned. For example, the interior of the shoe 12 can be scanned to determine the outline of the object 8. While in the case of a shoe 12 this can generally be done more easily by 3D scanning the standard insole 15 to be replaced, a 3D scanning of another object 6, such as, for example, the interior of a helmet, is easily possible.

[0111] The advantage of a scan of the object 7 to be replaced is that the size and in particular the outline 16 of the object 8 can be determined relatively easily and precisely.

[0112] The first data set 1 is sent to a server 17. This server 17 can be a central server, whereby the first data set 1 can be sent to this server 17 via the Internet. The second data set 2, if such a data set is recorded, is also sent to the server 17. The first data set 1 and, if applicable, the second data set 2 are used to create a 3D model 11 of the object 8, i.e., the customized insole 13. The first data set 1 essentially determines the shape of that side of the object 8 that is to rest against the scanned section of the person. The second data set essentially determines the external shape of the other surfaces or the contour or size of the object 8. Preferably, a third data set 3 is present, which corresponds to a reference model of the object 8.This reference model can then be adapted by including the first data set and, if applicable, the second data set 2 to create the individualized object 8.

[0113] If necessary, a fourth data set 4 is also included in the creation of the 3D model 11. This fourth data set 4 can, for example, specify further parameters of the object 8. Such parameters can relate to the density, stiffness, area of ​​application, or other parameters.

[0114] For example, the fourth data set 4 may also relate to adjustments to the 3D model 11 or the object 8 that are to be made for orthopedic or other reasons. For example, from an orthopedic perspective, it may be expedient not to exactly replicate the shape of the insole 13 with the shape of the foot 14, but rather to provide for targeted deviations.

[0115] For example, adjustments can also be made to increase comfort. In particular, the stiffness or density of a running shoe can be reduced or increased in another shoe, such as a ski boot.

[0116] These parameters can be queried, for example, via a user interface 25, which can be present on a mobile device, for example. The parameters can be entered by the person themselves, by trained specialists, or, for example, by an orthopedic surgeon.

[0117] A 3D model 11 is now created on the server 17, wherein at least the first data set 1, preferably the first data set 1, the second data set 2, the third data set 3 and the fourth data set 4 are included.

[0118] The 3D model 11 is transmitted to an additive manufacturing device 10. The additive manufacturing device 10 can be located at the same location as the server 17 or at any other location. For example, the device 10 can be located at the same location as the 3D scanning device 9. If the server 17 and the device 10 are not located at the same location, the 3D model 11 can be sent to the device 10, for example, via the Internet.

[0119] The 3D model 11 can be a digital 3D model in the conventional sense, or machine control data for the device 10, i.e., a 3D printer, can be transmitted. The device 10 is configured to produce the object 8, in this case, the insole 13, from the 3D model 11. It is preferably a 3D printer that operates according to the FDM method, i.e., the fused deposition modeling method.

[0120] According to one example, an air conditioning unit 24 can be provided for air conditioning areas of the additive manufacturing device 10. This air conditioning unit is preferably part of the device 10, i.e., in this case, part of the 3D printer.

[0121] An air-conditioned gas stream, in particular an air-conditioned air stream, can be introduced into the build space via the build space fan in order to air-condition it.

[0122] Additionally or alternatively, a gas stream from the air conditioning unit 24 can be introduced into the area where the printing material exits the print head 22 in molten form. This can be done, in particular, via a print head nozzle or a print head blower. According to the present example, this print head nozzle or the print head blower comprise a swirl nozzle 20.

[0123] Additionally or alternatively, the gas flow of the air conditioning unit 24 can be introduced into the area in which the printing material, and in particular the filament and in particular the filament spool, is / are provided. This allows the printing material itself to be air-conditioned.

[0124] Additionally or alternatively, the filament can also be cooled only in the area located directly in front of the print head 22. This allows the filament to be cooled on its outer surface, with the core of the filament possibly having a higher temperature. In the present illustration, in this embodiment, a line from the air conditioning unit 24 in the rear area could connect to the feed hose 23 in order to guide the conditioned gas flow through the feed hose 23. The conditioned gas flow can then exit, for example, via a nozzle in the area of ​​the print head 22, in particular via a swirl nozzle 20. Alternatively, a cooled ring element can also be provided which cools the filament on its outer surface before or upon entry into the print head 22. So that the core has a higher temperature than the outer surface of the filament, cooling of the filament spool can be omitted.

[0125] If necessary, air conditioning is provided by the air conditioning unit 24 immediately before and / or immediately after the print head 22. Air conditioning before the print head 22 can influence the behavior of the printing material during melting. Air conditioning after the print head 22 can influence the behavior of the printing material during curing.

[0126] To enter parameters when creating one or more 3D scans and also during the printing process, information can be exchanged with the user via a user interface 25.

[0127] If necessary, a circulating air flow is generated in the device 10, which is conditioned by the air conditioning unit 24. If necessary, fresh air is alternatively or additionally directed from the air conditioning unit 24 into the areas to be cooled or conditioned, and the air flow can then at least partially leave the device 10.

[0128] Figures 2a and 2b show schematic views and a sectional view, respectively, of a possible embodiment of a swirl nozzle 20. The swirl nozzle 20 has a nozzle ring 26 with a plurality of outlet openings 27. Furthermore, a plurality of nozzle channels 28 are provided, which exit through the outlet openings 27 on the nozzle ring 26. The nozzle channels 28 are, as can be seen particularly in Figure 2b, inclined or curved relative to the radial direction of the nozzle ring 26. This creates a twisted air flow, which runs in particular along the dispensed, molten printing material. The print head 22, and in particular the so-called hot end of the print head 22, extend into or through the interior of the nozzle ring 26. The nozzle ring 26 thus surrounds a portion of the print head 22. This discloses a print head 22 with a swirl nozzle 20.The print head 22 is preferably a print head 22 of a 3D printer that operates according to the FDM process, i.e. the fused deposition modeling process.

[0129] The nozzle ring 26 is annular, but may optionally be formed by segments or simply by outlet openings 27 arranged along a ring shape.

[0130] The special air discharge through the swirl nozzle 20 achieves particularly efficient and rapid cooling of the molten printing material. This can increase print quality and print speed.

[0131] Preferably, an air flow conditioned by an air conditioning unit 24 is passed through the vortex nozzle 20 and its nozzle channels 28 and outlet openings 27.

Claims

Patent claims 1. A method for producing an insole (13) customized for a specific person and for a specific shoe (12), comprising the following steps: - capturing a digital first data set (1) by 3D scanning the foot (14) or at least the underside of the foot of the person, - capturing a digital second data set (2) by 3D scanning at least part of the existing standard insole (15) of the shoe (12), - creating a digital 3D model (11) of the individualized insole (13) including the first data set (1) and the second data set (2), - additive manufacturing of the insole based on the 3D model (11 ).

2. Method according to claim 1, characterized in that the first data set (1) and the second data set (2) are acquired by the same 3D scanning device (9).

3. Method according to claim 1 or 2, characterized in that the first data set (1) and the second data set (2) are acquired by the 3D scanning device (9) of a mobile device, in particular a smartphone.

4. Method according to one of claims 1 to 3, characterized in that the acquisition of the first data set (1) is carried out by 3D scanning of the underside of the foot and additionally by 3D scanning of further regions of the foot (14), such as in particular the top of the foot, the heel region and / or the ankle region.

5. Method according to one of claims 1 to 4, characterized in that for capturing the second data set (2) the existing standard insole (15) of the shoe (12) is removed from the shoe (12) and 3D scanned.

6. Method according to one of claims 1 to 5, characterized in that to acquire the second data set (2) the outline (16) of the existing standard insole (15) of the shoe (12) is 3D scanned.

7. Method according to one of claims 1 to 6, characterized in that the existing standard insole (15) of the shoe (12) is replaced by the individualized insole (13).

8. Method according to one of claims 1 to 7, characterized in that a third data set (3) is included in the creation of the 3D model (11), wherein the third data set (3) is a data set of a reference model of an insole (13) which is adapted to the circumstances of the person and the shoe (12) by including the first data set (1) and the second data set (2).

9. Method according to one of claims 1 to 8, characterized in that - that the first data set (1 ) essentially determines the shape of the 3D model (11 ) on the upper side of the insole (13) facing the person's foot (14), - wherein the shape on the upper side of the insole (13) is orthopaedically corrected or adjusted if necessary.

10. Method according to one of claims 1 to 9, characterized in that the second data set (2) essentially determines the shape of the 3D model (11) on the surface facing the shoe (12) and thus the outline (16) of the insole (13).

11. Method according to one of claims 1 to 10, characterized in that a fourth data set (4) is included in the creation of the 3D model (11), wherein the fourth data set (4) determines the structure and in particular the lattice structure of the 3D model (11) of the insole (13) and thus physical parameters such as density and rigidity of the insole (13).

12. Method according to one of claims 1 to 11, characterized in that - that the first data set (1) and the second data set (2) are sent via the Internet to a central server (17), - and that the creation of the 3D model (11) of the insole (13) by the or on the central server (17), - and in particular that the 3D model (11) of the insole (13) is created by sending the first data set (1) and the second data set (2) to the server (17) and, if appropriate, receiving the 3D model (11) of the insole (13) from the server (17).

13. Method according to one of claims 1 to 12, characterized in that the filling of the insole (13) is grid-shaped and in particular has interconnected cavities or channels.

14. Method according to one of claims 1 to 13, characterized in that the insole (13) is formed at least partially, preferably completely, from a flexible 3D-printable material (21), in particular from TPU.

15. Method according to one of claims 1 to 14, characterized in that the additive manufacturing of the insole (13) is carried out by a 3D printer which operates according to the fused deposition modeling (FDM) method.

16. The method according to claim 15, characterized in that the air in the build space (18) of the 3D printer is cooled by active air conditioning by an air conditioning unit (24) with a build space fan (19) to a build space temperature of less than or equal to 20°C, preferably less than or equal to 15°C.

17. The method according to claim 15 or 16, characterized in that the air in the build space (18) of the 3D printer is conditioned by active air conditioning by an air conditioning unit (24) with a build space fan (19) to a relative humidity of less than or equal to 25%, preferably less than or equal to 20%.

18. Method according to one of claims 15 to 17, characterized in that in the region of the print head (22) of the 3D printer, an annular vortex nozzle (20) surrounding the print head (22) emits a twisted air stream along the output direction of the printing material (21).

19. Method according to one of claims 15 to 18, characterized in that the printing material (21) is cooled before and / or during processing in the 3D printer, in particular by the air conditioning unit (24).

20. Method according to one of claims 15 to 19, characterized in that the printing material (21) is cooled immediately before or upon entry into the print head (22), so that the printing material (21), in particular the filament, has a lower temperature in the region of its outer surface or surface than in the core region.

21. Method according to one of claims 1 to 20, characterized in that the additive manufacturing of the insole (13) takes place in a time of less than or equal to 20 minutes.

22. Arrangement for producing an insole (13) individualised for a specific person and for a specific shoe (12), comprising: - a 3D scanning device (9) for acquiring a digital first data set (1) by 3D scanning the bottom of the person's foot and for acquiring a digital second data set (2) by 3D scanning the existing standard insole (15) of the shoe (12), - a data processing arrangement, in particular a server (17), for creating a digital 3D model (11) of the individualised insole (13) by including the first data set (1) and the second data set (2), - and a 3D printer for additively manufacturing the insole (13) on the basis of the 3D model (11), characterized in that the arrangement carries out the method according to one of claims 1 to 21.

23. Insole manufactured by the method according to any one of claims 1 to 21 and / or on an arrangement according to claim 22.

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