Modular Foot Orthosis with Nested Flexible Molds
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Solution Overview
Problem
The logistics of transporting molds for custom foot orthotics from practitioners to manufacturers is time-consuming and depletes practitioner stock, and existing off-the-shelf orthotics are often uncomfortable and unstable, failing to address foot misalignments effectively.
Innovation Solution
A flexible support device that can be stored at the practitioner's location for reuse, allowing for on-site molding and adjustment, featuring a modular design with a rigid outer shell and soft inner shell for comfortable fit and proprioceptive feedback, enabling proper biomechanical alignment without the need for constant mold transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If molds are sent back to the manufacturer for custom foot orthotics, then custom fit is achieved, but logistics time is increased and practitioner stock is depleted
Solution Approach 1:
The device is divided into two functional parts: a reusable rigid support structure that remains at the practitioner's location, and a disposable flexible member that is sent to the manufacturer. This segmentation allows the practitioner to retain the essential support device while only transporting the consumable molding component, reducing logistics time and maintaining stock availability.
Solution Approach 2:
Instead of sending the entire custom orthotic mold back and forth, the system creates a negative mold using a flexible member that captures the foot impression. This copy of the foot shape is then used by the manufacturer to create the final orthotic, eliminating the need to transport the actual foot or full mold assembly repeatedly.
2Ease of operation
If multiple stock molds are kept at practitioner location, then molding capability is maintained, but storage space is consumed
Solution Approach 1:
The flexible members are designed to nest within each other when not in use, allowing multiple units to be stored in a compact configuration. The flexible member can be collapsed into a compact form that fits within the rigid support structure or a small storage container, dramatically reducing the space required to maintain inventory of multiple molding units.
3Ease of manufacture
If off-the-shelf orthotics are used, then cost is reduced, but comfort and stability are compromised
Solution Approach 1:
The orthotic device incorporates different materials with different properties in different regions: a rigid outer shell for structural support and stability, and a soft inner shell for patient comfort and adaptation to various foot shapes. This local differentiation of material properties allows the device to provide both comfort and stability simultaneously, resolving the trade-off between cost-effective off-the-shelf solutions and customized comfort.
4Manufacturing precision
If deep foot orthotics are designed for support, then biomechanical alignment is improved, but patient comfort is reduced
Solution Approach 1:
The device combines rigid and soft materials in a composite structure. The rigid portion provides the necessary biomechanical alignment and structural support, while the soft inner shell provides comfort and adapts to the patient's foot shape. This composite construction allows the device to deliver deep support for proper alignment while maintaining patient comfort through the compliant inner layer.
Data Source
AI summary
A corrective device to be worn on a human foot having a misalignment and positioned inside of footwear. The device having an inner shell having a first material composition and flexibility, and shaped to accommodate receiving therein and supportingly couple with the foot, and an outer shell having a second material composition and flexibility, the second material composition and flexibility being substantially the same as the first flexibility, the outer shell shaped to accommodate receiving therein the inner shell, supportingly couple with the inner shell and allow positioning into the footwear. At least a sufficient portion of a pressure is distributed by the outer shell and the inner shell over a desired area of the foot to provide an amount of correction to the misalignment while allowing the human to wear the inner shell inside of the outer shell inside of the footwear.