Biomimetic Orthopedic Footwear Advanced Insole Materials to Be Used in Medical Casts for Weight-Bearing Monitoring

Fabrication, characterization and testing of protective biomimetic orthopedic footwear advanced insole materials are introduced. The main objective of this material is to preserve and isolate a set of sensors for the Weight-Bearing Monitoring System (WBMS) device. Twenty-one samples of renewably sourced Polyurethane Foam (PUF) composed of poly(trimethylene ether) glycol (PO₃G) and unmodified castor oil (CO) were synthesized and evaluated according to predetermined criteria. Response surface methodology of Box-Behnken design was applied to study the effect of the polyols ratio, isocyanate index (II), and blowing agent ratio on the properties (hardness, density) of PUFs. Results showed that CO/PO₃G/Tolyene Diisocyanate (TDI) PUFs with hardness Shore A 17-22 and density of 0.19-0.25 g/cm³ demonstrate the required characteristics and can potentially be used as a durable and functional insole material. Phase separation studies have found the presence of well-segregated structures in PUFs having polyols ratio of CO:PO₃G 1:3 and low II, which further explains their extraordinary elastic properties (400% elongation). Analysis of cushioning performance of PUF signified that five samples have Cushioning Energy (CE) higher than 70 N·mm and Cushioning Factor (CF) in the range of 4-8, hence are recommended for application in WBMS due to superior weight-bearing and pressure-distributing properties. Moreover, the developed formulation undergoes anaerobic soil bacterial degradation and can be categorized as a "green" bio-based material.