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Automated rapid design method for personalized gradient pressure-relieving insoles.

Yanping Lin1, Jiarui Zhang1, Mian Ji1

  • 1School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, PR China.

Proceedings of the Institution of Mechanical Engineers. Part H, Journal of Engineering in Medicine
|September 13, 2025
PubMed
Summary

This study introduces an automated method for custom gradient pressure-relieving insoles. Personalized insoles effectively reduce foot pressure and enhance comfort, with rapid production cycles.

Keywords:
3D printingPressure-relieving insolesbiomechanicsplantar pressure distributionwearable devices

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Area of Science:

  • Biomedical Engineering
  • Orthotics and Prosthetics

Background:

  • Traditional insoles often lack personalized fit, leading to suboptimal pressure relief.
  • Existing design methods for pressure-relieving insoles can be time-consuming and inefficient.

Purpose of the Study:

  • To develop an automated, rapid design method for personalized gradient pressure-relieving insoles.
  • To improve the fit, design efficiency, and functional performance of custom insoles.

Main Methods:

  • Acquired and integrated subject-specific foot morphology and plantar pressure data.
  • Utilized the Point Cloud Library for designing structural units and generating insole contours.
  • Customized insoles for each subject and validated their effectiveness through comparative analysis.

Main Results:

  • Gradient pressure-relieving insoles significantly reduced peak plantar pressure compared to flat insoles.
  • Increased plantar contact area was observed with the gradient pressure-relieving insoles.
  • The complete design-to-production process was achieved within one week.

Conclusions:

  • Personalized gradient pressure-relieving insoles demonstrate effective functionality and adaptability.
  • The automated method offers a short production cycle, suitable for clinical applications.
  • This approach holds potential for advancing healthcare through improved orthotic solutions.