3D-Printed Orthotic Inserts From Foot Imaging and CAD Modeling
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Solution Overview
Problem
Existing methods for producing orthotic inserts are slow, expensive, and limited in customization, often providing one-size-fits-all solutions that do not optimally address individual patient needs, and are restricted to machining hard materials, limiting flexibility and shock absorption.
Innovation Solution
A method involving client devices capturing user data, generating three-dimensional models, and using parametric CAD models to produce orthotic devices through 3D printing, allowing for personalized customization and variable density inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional methods (plaster cast, gait scanning, laser scanning) are used to capture plantar geometry, then orthotic data can be obtained, but the process is slow, expensive, and limited in customization range
Solution Approach 1:
The patent replaces traditional mechanical scanning systems (laser scanners, gait scanning equipment) with a mobile imaging system using standard cameras or smartphones. The system captures multiple images of the foot from different angles and uses image processing algorithms to generate 3D models and orthotic prescriptions, eliminating the need for expensive, time-consuming mechanical scanning equipment while maintaining measurement accuracy.
Solution Approach 2:
The system creates digital copies of the foot geometry through image capture and processing, generating virtual 3D models and parametric CAD designs. This digital copying approach replaces physical plaster casting and mechanical measurement, enabling rapid reproduction and customization of orthotic designs without repeated physical measurements.
2Strength
If traditional machining methods are used to produce orthotic inserts, then hard materials can be processed, but flexibility, shock absorption, and customization are limited
Solution Approach 1:
The patent changes the manufacturing parameters from traditional machining to additive 3D printing processes. This enables the use of diverse materials with varying properties (flexibility, shock absorption, density) and allows for complex internal structures and variable thickness profiles that cannot be achieved through subtractive machining, thereby improving both customization capability and material performance characteristics.
Solution Approach 2:
The system enables the use of composite materials and multi-material 3D printing to create orthotic inserts with spatially varying properties. Different regions of the orthotic can be printed with different materials or densities to optimize flexibility, shock absorption, and support where needed, while maintaining overall structural integrity.
3Reliability
If orthotic devices are customized to particular ailments, then treatment specificity is improved, but the solution becomes one-size-fits-all rather than optimally tailored to individual patients
Solution Approach 1:
The patent applies local quality by enabling different regions of the orthotic device to have different properties (density, thickness, material composition) based on specific patient needs and pressure distribution requirements. The system analyzes foot anatomy and pressure points to create spatially varying characteristics throughout the orthotic, rather than uniform design, allowing optimal treatment for individual patient conditions.
Solution Approach 2:
The system creates dynamically adaptable orthotic designs that can respond to individual patient biomechanics. Through parametric CAD modeling and 3D printing, the orthotics can incorporate flexible regions, adjustable features, and anatomically precise contours that adapt to the patient's specific foot shape, gait pattern, and biomechanical requirements, moving beyond static one-size-fits-all solutions.
Data Source
AI summary
A method for generating an orthotic device is disclosed. The method includes receiving data from a client device of a patient, the data comprising patient information and image data representative of a body part of the patient. The method further includes generating, based on the image data, three-dimensional model data representative of the body part.