Custom Foot Orthotic With 3D Pressure-Guided Density Profiling
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Solution Overview
Problem
Conventional foot orthotics rely heavily on subjective opinions and do not effectively address functional forces during human movement, leading to ineffectiveness in providing comfort and correcting foot issues due to lack of objective data on underfoot pressure distribution.
Innovation Solution
A system and method utilizing a plantar pressure sensor array and 3D scanner to generate a custom foot orthotic design by superimposing desirable pressure distribution over a 3D model, adjusting density and elevation to match the expected pattern of support, and producing the orthotic using Fused Deposition Modeling for optimal fit and function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional foot orthotics are customized based on subjective opinion, then the orthotic can be tailored to the patient's foot shape, but the effectiveness is reduced due to lack of objective pressure distribution data
Solution Approach 1:
The patent replaces subjective visual inspection and manual assessment with an automated plantar pressure sensor array system that objectively measures pressure distribution. This substitution of mechanical/measurement systems eliminates reliance on operator subjectivity and provides quantifiable pressure data for orthotic design.
Solution Approach 2:
The system allows the orthotic design process to serve itself by automatically generating design recommendations based on measured pressure data, reducing the need for expert subjective judgment. The computer system processes the pressure distribution data and autonomously determines optimal orthotic configurations.
2Ease of manufacture
If the orthotic design process is simplified using conventional methods, then it is easier to manufacture, but it fails to address functional forces during human movement
Solution Approach 1:
The system performs preliminary measurement and analysis of pressure distribution during the design phase, before manufacturing begins. This advance characterization of functional forces allows the orthotic to be pre-configured with appropriate density variations that will address movement-related issues, combining ease of manufacture with functional reliability.
Solution Approach 2:
The patent applies local quality by varying the density of the orthotic material at different locations based on measured pressure distribution. Areas of high pressure receive different material properties than low-pressure areas, allowing the single orthotic device to address multiple functional requirements while maintaining ease of manufacture through a unified manufacturing process.
3Manufacturing precision
If variable density is implemented in the orthotic to address pressure distribution, then comfort and correction effectiveness improve, but manufacturing complexity increases
Solution Approach 1:
The patent changes the material parameter of density in a controlled manner based on pressure distribution data. By systematically varying density as a function of measured pressure, the system achieves precise control over orthotic performance while the automated process keeps manufacturing complexity manageable.
Solution Approach 2:
The orthotic utilizes composite material structures with varying density regions, combining different material properties within a single device. This allows the orthotic to address multiple pressure zones with appropriate material characteristics while being manufactured as an integrated unit, balancing manufacturing precision with process feasibility.
Data Source
AI summary
A custom foot orthotic and a system and a method for designing of a custom foot orthotic. The method includes: receiving 3D scan data of the patient's foot; receiving plantar pressure scan data of the patient's foot; establishing a desirable pressure distribution; generating an underfoot elevation profile relative to an elevation profile of the patient's foot in the 3D scan data; determining an internal density profile of the resulting foot orthotic 3D model by superimposing the desirable pressure distribution over the resulting foot orthotic 3D model and reducing or increasing density in regions of the foot orthotic 3D model based on the difference between an expected pattern of support and the desirable pressure distribution; and outputting the 3D model of the custom foot orthotic.