Custom Orthopedic Inserts Using Graduated 3D Printed Layers
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Solution Overview
Problem
Conventional orthopedic inserts for footwear are either universal and inexpensive for comfort or custom-made by podiatrists to correct leg length discrepancies and spinal deformities, but these are costly and require multiple visits, often not addressed until chronic problems manifest, leading to later-life issues like scoliosis and back pain.
Innovation Solution
A method using digital measurements and 3D printing to create custom orthopedic inserts with graduated layers that can be added over time to correct spinal deformities and leg length discrepancies, reducing the need for costly podiatrist visits and traditional casting processes, utilizing a computer-connected 3D printer to design and manufacture inserts based on patient data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom orthopedic inserts are made by podiatrists using traditional casting methods, then correction effectiveness is improved, but cost and time consumption increase significantly
Solution Approach 1:
The patent replaces the traditional mechanical casting system with a digital imaging and 3D printing system. Digital X-ray and scanning technologies capture foot anatomy, which is then processed by computer software to design corrective inserts. These designs are manufactured using 3D printing technology, eliminating the need for physical casting materials and multiple adjustment visits, while maintaining correction effectiveness.
Solution Approach 2:
The patent transforms the physical casting process into digital parameters through scanning and imaging. The foot's anatomical parameters are captured digitally, allowing for precise measurement and analysis without physical contact. This parameter transformation enables remote design and manufacturing, reducing time loss while preserving correction accuracy.
2Adaptability or versatility
If custom orthopedic inserts are made by podiatrists, then personalized correction is improved, but cost increases significantly
Solution Approach 1:
The patent enables patients to obtain custom orthopedic inserts through a self-service digital process. After initial digital scanning and diagnosis, patients can receive their personalized inserts through automated 3D printing, reducing dependency on repeated podiatrist visits. This self-service model maintains personalized correction while significantly reducing the cost associated with professional service time and materials.
Solution Approach 2:
The patent creates digital copies of the patient's foot anatomy through scanning and imaging technologies. These digital models serve as accurate replicas that can be manipulated, analyzed, and used for design without requiring physical casts or repeated professional measurements. The digital copying process enables personalized correction at lower cost by eliminating physical material expenses and professional service fees.
3Measurement precision
If traditional casting methods are used, then anatomical accuracy is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces complex mechanical casting procedures with digital imaging and computational design systems. Digital X-ray, laser scanning, or photogrammetry technologies capture anatomical surfaces with high precision, eliminating the need for physical molding materials, casting equipment, and manual shaping processes. The computational software automatically processes the digital data to generate precise anatomical models and insert designs.
Solution Approach 2:
The patent creates accurate digital copies of anatomical structures through non-contact scanning methods. These digital replicas capture surface geometry and internal structure with high precision, replacing physical casts that require complex molding, setting, and processing. The digital copying process simplifies the entire workflow while maintaining or improving measurement accuracy through automated data capture and processing.
Data Source
AI summary
Systems and methods of measuring feet and designing and creating orthopedic inserts are described. A leg length discrepancy of a user is measured and this data, along with foot size are input into a computer. The computer then creates a computer model of a custom shoe insert based on this information. The computer model is then sent to a 3D printer to print the insert. The insert consists of a base insert with partial correction, and several additional layers that are added successively over time until a full correction is obtained. This eliminates any pain associated with a fully corrective insert, and allows the body to adjust gradually to the correction.