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Durability and offloading performance of 3D-printed multilayer lattice for accommodative insoles
Avocet Y Nagle-Christensen1, Dylan Heino2, Kimberly A Nickerson2
1VA RR&D Center for Limb Loss and MoBility (CLiMB), VA Puget Sound Health Care System, 1660 S Columbian Way, MS 151, Seattle, WA, 98108, USA.
Summary
3D-printed insoles show superior long-term durability compared to standard foam options. These advanced lattice structures effectively reduce plantar pressure, offering a more resilient solution for diabetic foot ulcer prevention.
Area of Science:
- Biomedical Engineering
- Materials Science
- Podiatry
Background:
- Standard of care (SoC) accommodative insoles, made from multilayer foams, are used to offload high plantar pressures in diabetic individuals at risk of foot ulceration.
- SoC insoles can deform over time, diminishing their effectiveness in pressure reduction.
- 3D-printed elastomeric polyurethane (EPU) multilayer lattice structures show promise in matching SoC foam properties and reducing plantar pressures.
Purpose of the Study:
- To investigate the long-term pressure offloading performance and durability of 3D-printed EPU multilayer lattice insoles compared to SoC foam insoles.
- To assess the mechanical integrity and pressure reduction capabilities of both materials under cyclic loading.
Main Methods:
- 3D-printed EPU multilayer lattice pucks and SoC multilayer foam pucks were subjected to one million cycles of sinusoidal compressive loading.
- Testing was conducted under both uniform and uneven loading conditions, with and without designed offloading regions.
- Peak pressure (PP), pressure time integral (PTI), residual thickness, and elastic modulus were measured throughout the testing period.
Main Results:
- Under uniform loading, both materials maintained stable peak pressures below the 200 kPa clinical threshold after one million cycles.
- Under uneven loading, SoC pucks showed significant increases in pressure and up to 36% reduction in thickness, while 3D-printed pucks maintained structural integrity with ≤3% thickness reduction and reduced PP over time.
- Both materials with designed offloading regions kept PPs below 150 kPa throughout testing.
Conclusions:
- 3D-printed multilayer lattice materials demonstrate superior durability and long-term pressure offloading efficacy compared to traditional foam insoles, particularly under uneven loading conditions.
- These findings suggest that 3D-printed lattice structures are a promising alternative for developing durable and effective long-term pressure reduction strategies for at-risk diabetic populations.
- Further investigation into clinical applications of these advanced materials is warranted.
