3D Printed Meshed Damping Element for Custom Insole Morphology
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Solution Overview
Problem
Current insole manufacturing processes are artisanal, non-standardized, and inefficient, requiring multiple toxic materials and resulting in material loss and inadequate control over mechanical properties, which limits the ability to achieve targeted damping and adaptation to individual foot morphology.
Innovation Solution
A method for manufacturing insoles using 3D printing to create a meshed structure with adjustable hardness, allowing for localized control of mechanical properties and reduced material usage, featuring a damping element with a meshed structure between two layers that can be customized for specific foot shapes and needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional artisanal manufacturing processes are used to create insoles with interlayer elements, then the insoles can provide proprioceptive and exteroceptive stimulation, but the manufacturing process is non-standardized, requires about 45 minutes per insole, uses toxic chemicals and solvents, and results in material loss of about 25%
Solution Approach 1:
The patent changes the manufacturing parameters from traditional artisanal methods to 3D printing technology, enabling standardized production while maintaining customizability. The 3D printing process allows precise control of material deposition parameters, build orientation, and layer thickness, achieving consistent mechanical properties with reduced manufacturing time and material waste.
Solution Approach 2:
The patent replaces the mechanical subtractive manufacturing process (milling machines) with an additive 3D printing system. This substitution eliminates the need for material removal, reducing material loss from 25% to minimal waste, while also eliminating exposure to toxic chemicals and solvents used in traditional bonding processes.
2Reliability
If multiple different materials are combined to achieve targeted mechanical properties in insoles, then the insole can provide desired damping and propulsion properties, but the manufacturing process becomes more complex and requires exposure to toxic chemicals and solvents
Solution Approach 1:
The patent employs composite material strategies through 3D printing, where a single material is deposited in complex geometries that inherently provide the desired mechanical properties. The lattice structures and varying wall thicknesses created by 3D printing achieve damping and propulsion functions without requiring multiple material combinations, thereby reducing chemical complexity while maintaining performance.
Solution Approach 2:
The patent applies local quality by varying the structural properties at different locations within the insole through 3D printing. The lattice geometry, cell size, and wall thickness are locally optimized to provide specific mechanical properties at each region, eliminating the need for multiple materials while achieving targeted damping and propulsion characteristics.
3Adaptability or versatility
If subtractive manufacturing processes are used to create interlayer elements, then the insole can be customized to individual foot morphology, but about 25% of material boards are lost during manufacturing
Solution Approach 1:
The patent applies preliminary action by creating a digital 3D model of the patient's foot morphology before manufacturing. The insole design is virtually optimized and validated in the digital domain, ensuring perfect fit and function before physical production. This pre-planning enables precise material usage in 3D printing, eliminating the 25% material loss associated with subtractive manufacturing while maintaining full customization capability.
4Reliability
If the insole comprises damping material over its whole surface, then the insole provides general cushioning, but it is not efficient for certain applications such as palliative applications where localized control is needed
Solution Approach 1:
The patent implements local quality by designing the insole with spatially varying lattice structures through 3D printing. Different regions of the insole have different cell sizes, wall thicknesses, and lattice geometries, enabling localized control of damping properties. This allows high damping in areas requiring cushioning while providing lower damping or firm support in areas requiring sensory feedback or bone alignment, achieving both overall damping performance and localized adaptability.
Data Source
Figure 1~2A
Figure 2B~2E
Figure 3~4
AI summary
The present invention relates to a damping element (1) comprising: a first structure (2) and a second structure (4) forming respectively an inferior surface (3) and a superior surface (5); and a meshed structure (6) comprised between the inferior surface (3) and the superior surface (5); the first structure (2), the second structure (4) and the meshed structure (6) being designed in a same monobloc part. The present invention further relates to an insole and a shoe comprising at least one damping element (1). The present invention further relates to a method for modeling a damping element (1) for an insole.