Custom Insole Fabrication via Non-Weight-Bearing 3D Printing
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Solution Overview
Problem
Existing methods for creating custom footwear insoles require weight-bearing foot measurements, which can exacerbate irregularities and abnormalities, and involve cumbersome, expensive equipment that necessitates delays and additional visits for patients, as well as costly shipping and maintenance.
Innovation Solution
A system that uses non-weight-bearing foot scanning technology to generate a 3D printable file, which is sent to a remote server for processing and returned to the podiatrist's office for fabrication using multi-material 3D printing, allowing for same-day custom insole creation without the need for expensive hardware upgrades or periodic maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight-bearing foot measurements are used, then the foot structure can be captured under load, but irregularities and abnormalities are exacerbated
Solution Approach 1:
The patent inverts the conventional approach by scanning the foot in a non-weight-bearing position (supine) rather than weight-bearing position. This inversion allows the foot to be scanned in a relaxed, natural state, avoiding the deformities caused by pressure while still capturing the essential foot structure for custom insole fabrication.
2Ease of manufacture
If traditional CNC routing or carving tools are used, then custom orthotics can be fabricated, but the equipment is noisy, dangerous and difficult to maintain
Solution Approach 1:
The patent replaces traditional mechanical CNC routing and carving tools with additive manufacturing technology (3D printing). This substitution eliminates the noisy, dangerous, and maintenance-intensive mechanical cutting processes, providing a safer, cleaner, and easier-to-maintain fabrication method for custom orthotics.
Solution Approach 2:
The patent changes the manufacturing parameters from subtractive manufacturing (removing material) to additive manufacturing (depositing material). This fundamental parameter change transforms the fabrication process from noisy mechanical cutting to controlled material deposition, reducing safety hazards and maintenance requirements while maintaining customization capability.
3Ease of manufacture
If CNC machines are used outside the podiatrist's office, then custom orthotics can be fabricated, but delays and shipping costs are required
Solution Approach 1:
The patent merges the scanning, digital design, and 3D printing functions into a single integrated system that can be deployed within the podiatrist's office. This consolidation eliminates the need to send foot impressions to external labs, reducing fabrication time and eliminating shipping costs while maintaining custom orthotic fabrication capability.
Solution Approach 2:
The patent enables the podiatrist's office to perform self-service fabrication of custom orthotics using in-office 3D printing equipment. This self-service capability eliminates dependency on external fabrication facilities, allowing immediate production of custom orthotics without shipping delays or additional patient visits.
4Adaptability or versatility
If multi-material printers are used, then materials with different characteristics can be combined, but the equipment complexity increases
Solution Approach 1:
The patent utilizes multi-material 3D printing technology to create composite insoles combining different materials with complementary properties (e.g., rigid support materials and flexible cushioning materials). This allows the insole to simultaneously provide structural support and comfort, achieving functional versatility through material composition rather than complex mechanical structures.
Data Source
AI summary
A custom insole and process for fabrication comprised of scanning to map a foot, sending the scan to a remote processing computer and returning a 3D compatible printable file that can render the custom insole in a short time. The foot is preferably not deformed by standing pressure during the scan. The podiatrist taking the scan can amend the electronic file to add or remove material from the yet-to-be-made custom insole to tailor the fit to the specific patient.