3D-Printed Orthopedic Inserts for Gradual Leg Length Correction

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Solution Overview

Problem

Existing orthopedic inserts for footwear are either universal and inexpensive for comfort or custom-made by podiatrists to correct leg length discrepancies and spinal deformities, which are costly and require multiple visits, often leading to undetected chronic problems until permanent damage occurs.

Innovation Solution

A method using digital measurements and 3D printing to create customizable orthopedic inserts with graduated layers that correct spinal deformities and leg length discrepancies, reducing the need for costly podiatrist visits and traditional casting processes, by utilizing digital cameras, software, and 3D printers to manufacture inserts based on individual anatomical data.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If custom orthopedic inserts are made by podiatrists using traditional casting methods, then the inserts can correct leg length discrepancies and spinal deformities, but the process is costly and requires multiple visits

Engineering Contradiction:

Improvecorrection effectivenessVSAvoidnumber of visits

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the traditional mechanical casting process with digital imaging and 3D printing technology. Digital cameras capture foot images, software processes them to create corrective inserts, and 3D printers manufacture the inserts, eliminating the need for physical casts and multiple in-person visits while maintaining correction effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates digital copies of the patient's foot anatomy through photography and image processing. These digital models are then used to generate and print corrective inserts, replacing the traditional physical casting process and enabling remote customization without requiring multiple visits to the podiatrist

Inventive Principle:

Principle #26Copying

2Reliability

If custom orthopedic inserts are made by podiatrists, then the inserts can correct spinal deformities, but the process is expensive

Engineering Contradiction:

Improvecorrection effectivenessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive manual casting and manufacturing processes with automated 3D printing technology. The digital workflow from image capture to insert production eliminates labor-intensive steps and reduces manufacturing costs while maintaining the ability to correct spinal deformities effectively

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing parameters from traditional casting materials and methods to 3D printing materials and processes. This parameter change enables cost-effective production of custom inserts while maintaining the medical effectiveness required for correcting leg length discrepancies and spinal deformities

Inventive Principle:

Principle #35Parameter changes

3Reliability

If traditional casting methods are used, then custom inserts can be made, but the process is time-consuming and delays correction

Engineering Contradiction:

Improvecorrection effectivenessVSAvoidinsert production speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the time-consuming traditional casting process with rapid 3D printing technology. Digital images are processed quickly by software, and the 3D printer can produce custom inserts in a fraction of the time required for traditional methods, enabling faster correction while maintaining effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent performs preliminary digital scanning and modeling of the patient's foot anatomy before manufacturing begins. This preliminary action allows for immediate processing and production, eliminating the waiting time associated with traditional casting methods and enabling faster delivery of corrective inserts

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach provides a cost-effective and efficient solution for correcting leg length discrepancies and spinal deformities, potentially preventing long-term issues like scoliosis and back problems by allowing for gradual correction over time, reducing pain and the economic burden of traditional custom inserts.

Implementation Method 1

manufacturing the orthopedic insert based on the design

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Data Source

PatentUS11259951B2Method for creating custom orthopedic supports from computerized data inputs

Publication Date: 2022.03.01 SPECTOR DONALD

AI summary

Systems and methods of measuring feet and designing and creating orthopedic inserts are described. A leg length discrepancy of a user is measured and this data, along with foot size are input into a computer. The computer then creates a computer model of a custom shoe insert based on this information. The computer model is then sent to a 3D printer to print the insert. The insert consists of a base insert with partial correction, and several additional layers that are added successively over time until a full correction is obtained. This eliminates any pain associated with a fully corrective insert, and allows the body to adjust gradually to the correction.