3D Printed customized diabetic foot insoles with architecture designed lattice structures - a case study

Area of Science:

• Biomedical Engineering
• Materials Science
• Podiatry

Background:

• Diabetic foot ulcers are a significant complication, often caused by prolonged plantar pressure.
• Current insoles may not adequately address the need for customized support and pressure redistribution in high-risk individuals.
• 3D printing offers a pathway to personalized medical devices, including footwear components.

Purpose of the Study:

• To design and evaluate custom 3D printed insoles with architectural lattice infills for diabetic patients.
• To compare the effectiveness of five different lattice structures (Fluorite, Kelvin, Octet, Isotruss, Truncated Octahedron) in managing plantar pressure and weight.
• To identify an optimal lattice design for enhanced foot support and cushioning in ulcer-prone feet.

Main Methods:

• Utilized 3D printing technology to create custom insoles with internal lattice structures.
• Analyzed five distinct architectural lattice unit cells for their mechanical properties and performance.
• Evaluated lattice configurations based on their ability to redistribute plantar pressure and support body weight.

Main Results:

• The Kelvin lattice structure exhibited the lowest stiffness among the tested configurations.
• This minimal stiffness suggests superior performance in balancing plantar pressure and weight distribution.
• Lattice-structured insoles provide enhanced cushioning and support compared to traditional designs.

Conclusions:

• Architectural lattice structures, particularly the Kelvin design, represent a promising innovation for diabetic foot care.
• Custom 3D printed insoles can be optimized to reduce the risk of foot ulcers in diabetic patients.
• This study provides valuable insights into the selection of lattice designs for effective plantar pressure management.