Modular Foot Sole Last for Custom Insole Production
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Solution Overview
Problem
The existing methods for manufacturing insoles, such as the 'drawer technique' and CNC milling, fail to provide patient-specific adaptations, leading to high complaint rates and are economically and technically inefficient, with high acquisition and maintenance costs, and significant waste generation.
Innovation Solution
A method utilizing a modular-structure foot sole last divided into zones, where patient-specific data is used to select and arrange standard modules and determine thermoplastic material properties, allowing for the production of individualized insoles via heat and vacuum pressing, eliminating the need for on-site CNC milling machines and reducing production time and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the drawer technique is used to prepare insoles, then ready-made insoles can be selected from stock, but the insoles are not sufficiently adapted to patient-specific individual needs
Solution Approach 1:
The foot sole last is divided into multiple zones (heel zone, midfoot zone, forefoot zone, toe zone), each with specific geometric parameters that can be independently adjusted based on patient data, allowing zone-specific adaptation while maintaining ease of manufacture
Solution Approach 2:
The invention uses patient-specific measured values (foot length, width, gait parameters, pressure distribution) to calculate and adjust geometric parameters of the foot sole last, such as curvature radii, angles, and dimensions, enabling customization without complex manufacturing
2Adaptability or versatility
If CNC milling machines are used to produce individualized sole lasts, then patient-specific insoles can be manufactured, but acquisition costs, operating costs, and maintenance costs are particularly high
Solution Approach 1:
The invention replaces the mechanical CNC milling process with a computational geometry approach that calculates the foot sole last parameters directly from patient data using mathematical formulas and algorithms, eliminating the need for expensive milling machinery
Solution Approach 2:
Instead of milling the sole last from a solid block (subtractive manufacturing), the invention generates the sole last geometry through computational modeling and creates it by adding material or forming processes, reducing waste and equipment requirements
3Adaptability or versatility
If CNC milling is used to create sole lasts, then individualized insoles can be produced, but the milling process requires significant time (about 15 minutes per sole last)
Solution Approach 1:
The invention performs preliminary calculations of all geometric parameters of the foot sole last before manufacturing begins, using patient data to pre-determine the exact dimensions and shapes needed, eliminating time-consuming trial-and-error or iterative milling processes
Solution Approach 2:
The computational method allows rapid recalculation and adjustment of geometric parameters based on patient measurements, enabling quick customization without the fixed 15-minute milling cycle time
4Adaptability or versatility
If CNC milling is used to produce sole lasts, then individualized insoles can be manufactured, but large amounts of material waste accumulate from milled residues
Solution Approach 1:
The invention changes the manufacturing approach from subtractive (milling away material) to additive or formative processes, where the sole last is created by building up or shaping material according to calculated parameters, eliminating milled waste
Solution Approach 2:
The computational geometry method optimizes material usage by precisely calculating the required sole last dimensions from patient data, minimizing excess material that would become waste during manufacturing
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 method enables the production of highly individualized insoles that accurately meet patient needs, reducing complaint rates, eliminating the need for CNC milling machines, and minimizing production time and waste, while allowing untrained personnel to create insoles efficiently.
Implementation Method 1
to produce an individualized insole from a thermoplastically deformable material by heating and vacuum pressing the material onto the individual foot sole last
Implementation Method 2
by heating and vacuum pressing the material onto the individual foot sole last
Data Source
AI summary
Method for producing an individual foot sole last (15) for a patient (10) or sportsman by reference to measured values and/or medical findings which are obtained from the body of the patient (10) or sportsman, characterized in that the individual foot sole last (15) is constructed of individual pre-fabricated standard modules (17), wherein the standard modules (17) are selected from a module set, whereby by reference to the measured values and/or medical findings which are obtained from the body of the patient (10) or sportsman, an actual value for the foot mould is determined and this is compared with one or more predefined desired values and by reference to the result of the comparison and the knowledge of the standard modules (17) present in the module set, those standard modules (17) are selected and combined in their sequence—or specified in their sequence—which come closest to the ideal individual foot sole last (15) determined by reference to the comparison of actual and desired value.