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Design and development of fused deposition modeling (FDM) 3D-Printed Orthotic Insole by using gyroid structure
Uday Kumar Jonnala1, Rakesh Sankineni1, Y Ravi Kumar1
1Department of Mechanical Engineering, National Institute of Technology, Warangal, India.
Summary
Custom 3D-printed orthotic insoles can be designed using computer-aided design (CAD) software and pressure mapping data. Gyroid structures offer superior energy absorption compared to solid designs for enhanced foot biomechanics.
Area of Science:
- Biomechanics
- Materials Science
- Additive Manufacturing
Background:
- Orthotic insoles support the foot, influencing body biomechanics by reducing plantar pressure.
- Traditional custom insole fabrication relies on manual or subtractive methods.
- Fused Deposition Modeling (FDM) presents new manufacturing possibilities for orthotic insoles.
Purpose of the Study:
- To evaluate existing computer-aided design (CAD) techniques for fabricating custom orthotic insoles.
- To explore the functionalization of insole materials and structures.
- To develop a novel CAD approach for personalized insole design.
Main Methods:
- Utilized multiple software tools for designing custom insoles based on 3D foot scans and pressure points.
- Integrated pressure mapping data into the CAD process for enhanced customization.
- Fabricated insoles using soft poly-lactic acid (PLA) via FDM technology, comparing gyroid and solid structures.
Main Results:
- The study demonstrated significant customization potential by integrating pressure mapping data into CAD.
- Gyroid structures exhibited higher specific energy absorption than solid constructions.
- Infill density was identified as a critical parameter influencing structural selection for custom insoles.
Conclusions:
- Established CAD techniques, combined with FDM, enable effective design and fabrication of customized orthotic insoles.
- Gyroid infill structures are advantageous for orthotic insole applications due to superior energy absorption.
- Further research into infill density optimization can enhance custom insole performance.
